EP0703307A1 - Textile composite, textile composite pocket and method of producing a composite part from such a textile or pocket - Google Patents

Textile composite, textile composite pocket and method of producing a composite part from such a textile or pocket Download PDF

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Publication number
EP0703307A1
EP0703307A1 EP95402095A EP95402095A EP0703307A1 EP 0703307 A1 EP0703307 A1 EP 0703307A1 EP 95402095 A EP95402095 A EP 95402095A EP 95402095 A EP95402095 A EP 95402095A EP 0703307 A1 EP0703307 A1 EP 0703307A1
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EP
European Patent Office
Prior art keywords
composite
composite textile
textile
pocket
film
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EP95402095A
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German (de)
French (fr)
Inventor
Pierre Davoine
Jean-Claude Berthier
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SARL ADN
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    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/42Non-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
    • D04H1/4209Inorganic fibres
    • D04H1/4218Glass fibres
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H1/00Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40Non-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
    • D04H1/58Non-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 by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
    • D04H1/64Non-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 by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives the bonding agent being applied in wet state, e.g. chemical agents in dispersions or solutions
    • D04H1/645Impregnation followed by a solidification process
    • DTEXTILES; PAPER
    • D04BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04HMAKING 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
    • D04H13/00Other non-woven fabrics

Definitions

  • the invention relates to a composite textile, a composite textile pocket and a method of manufacturing a composite part from such a composite textile and / or from such a composite textile pocket.
  • the invention finds an application in particular whenever it is desired to manufacture a composite part having good mechanical strength for a low weight.
  • the object of the invention is to propose a method of manufacturing composite parts which overcomes the drawbacks or limits of those known in the art.
  • Another object of the present invention is to provide a composite textile and a pocket of composite textile whose use in the process for manufacturing the composite parts according to the invention makes it possible to greatly reduce the number of steps in the process and, thereby even, to speed up manufacturing.
  • the invention firstly proposes a composite textile, intended in particular to be coated with a coating resin, characterized in that it comprises an extensible film comprising a front face and a back face, the face front being covered substantially over its entire length successively with at least one felt of preformable glass fibers agglomerated by a thermoplastic binder and at least one nonwoven veil of glass fibers.
  • the invention also provides a pocket of composite textile intended in particular to be coated with a coating resin, characterized in that it consists of two composite textiles secured to each other by the back side of the extensible film along a joining line .
  • the invention allows, by the use of a composite textile of a particular structure and a pocket made from this composite textile, the easy, reliable and economical manufacture of any type of composite part. .
  • the invention therefore relates to the field of composite parts. Such parts find their application whenever one wishes parts having good mechanical strength for a low weight. These parts are generally intended to be coated with a resin coating, then possibly, lacquer, varnish, paint or equivalent.
  • the invention therefore relates first of all to a composite textile 1 characterized in that it comprises an extensible film 2 comprising a front side 2a and a back side 2b, the front side 2a being covered substantially over its entire length successively at least at least one felt 3 of preformable glass fibers agglomerated by a thermoplastic binder and at least one veil 4 of nonwoven of glass fibers.
  • This composite textile allows the production of a pocket which, according to the invention consists of two composite textiles 1 secured to each other by the back side 2b of the film 2 which can be extended along a joining line 6.
  • This pocket is intended to be filled with a polymerizable material, then coated with a coating resin.
  • the veil 4 consisting of a nonwoven of extremely compacted glass fibers, has as its first function that of finishing. By playing the role of mechanical barrier, it prevents the coarse glass fibers of the felt 3 from appearing on the surface of the composite part made from the composite textile. It therefore improves the finish appearance of the surface of the composite part which will subsequently receive the coating resin. Consequently, it is obviously necessary for this veil 4 of nonwoven and of glass fibers to be able to withstand the conditions of injection of the coating resin.
  • the felt 3 of glass fibers is preformable, which makes it possible to use, at the time of the actual molding, a reinforcement which is already in the shape of the part to be manufactured.
  • the felt 3 of glass fibers is also agglomerated by a thermoplastic binder, which allows on the one hand its association with the extensible film 2 and on the other hand, improves the preformability of the felt 3.
  • This felt 3 can be made up of several layers of glass fibers of different titles.
  • the felt 3 may consist of a layer of 50 tex threads sandwiched between two layers of 25 tex threads.
  • the felt 3 of glass fibers can also comprise a metallic insert such as for example electric pins, a plastic or composite insert.
  • the film 2 is thermoplastic. It has a thickness between 25 ⁇ m and approximately 1 mm, preferably of the order of 50 ⁇ m and can be multilayer.
  • the film 2 is composed of polyesterurethane.
  • it can also be based on polyetherurethane or polyamide, the main thing being that it fulfills the specifications defined above.
  • This composite textile 1 is intended to be used in the form of a pocket 5 which, during the process for manufacturing the composite part, will be filled with a polymerizable material.
  • this polymerizable material is a polyurethane foam with a density of between 0.1 and 0.9 g / cm3 and, preferably, between 0.3 and 0.4 g / cm3.
  • this polymerizable material can be of any type such as, in particular, polyvinyl chloride (PVC).
  • the formulation of the polyurethane foam can be adapted to have a skin effect, that is to say to have a high density on the surface and a lower density at the heart.
  • the polymerizable material can also comprise a metallic, plastic or composite insert and it can be loaded for example with glass or ceramic microbeads or glass microfibers.
  • the composite textile 1 according to the invention is manufactured by successively placing on a work surface (which may possibly be a mold) the extensible film 2, at least the felt 3 of preformable glass fibers agglomerated by a thermoplastic binder and at least the veil 4 of glass fiber nonwoven.
  • the veil 4 of non-woven glass fibers can be placed, not at this stage, but at the time of the stage of manufacturing the pocket 5 of composite textile.
  • the composite fabric 1 is then heated by passage through an oven (radiant, hot air, etc.) to a temperature between 80 and 110 ° C.
  • This heating allows on the one hand the thermoplastic binder of the felt 3 to act, and, on the other hand, the thermoplastic film 2 to soften, the result of this heating being the intimate association of the web 4 of nonwoven fibers of glass, of the felt 3 of glass fibers and of the thermoplastic film 2.
  • the composite textile 1 can be cooled and stored.
  • This step consists in superimposing two composite textiles 1 obtained in the previous step, by their back sides 2b of film 2, then in joining them together along a joining line 6 in relation to the shape of the composite part that is to be sought. to manufacture.
  • This joining of the two composite textiles 1 is carried out by welding means (heating, high frequency, ultrasound) or by bonding means (polyurethane glue, silicone, mastic).
  • a composite textiles 1 is then cut at the periphery of the joining line 6. This cutting is carried out at a distance of the order of 2 to 3 cm from the joining line 6 .
  • This step consists in placing the pocket 5 of composite textile obtained by the previous step in a mold so that it is contained in the mold but not maintained.
  • This mold can be made up of several movable or removable parts making it possible to facilitate and ensure proper placement of the bag 5, said parts being folded down before or during the injection of the polymerizable material.
  • the floating periphery 7 of the pocket 5 of composite textile is folded towards the center of said pocket.
  • cutting the cores of polymerizable material may possibly be necessary.
  • a coating resin can be injected directly after the injection of polymerizable material and therefore before the cooling mentioned above.
  • the residual injection core is cut from the injection of polymerizable material, without removing the part from the mold, then the coating resin is injected into the felt 3 of glass fibers.
  • This injection is carried out at a temperature of 80 ° C. under a pressure of 30 bars.
  • a finished composite part is obtained, that is to say coated with resin.
  • the mold and the polymerizable material must be able to withstand a pressure of 30 bars.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

A composite textile (1), partic. destined to be coated with an impregnating resin, consists of an extensible film (2) with the reverse face (2a) being completely covered with a felt (3) of preformed glass fibre agglomerated by a thermoplastic binder, and a sheet (4) of non-woven glass fibre. The extensible-film (2) is partic. polyether or polyester polyurethane, or polyamide; between 25 micron and 1 mm thick, pref. about 50 microns. The fibre glass felt may be of several layers and different types. Composite textile pockets (5) are made by joining film face to film face two layers of composite textile. These are partic. for filling with polymerisable material partic. polyurethane foam either filled or with metallic agents.

Description

L'invention concerne un textile composite, une poche de textile composite et un procédé de fabrication d'une pièce composite à partir d'un tel textile composite et/ou d'une telle poche de textile composite.The invention relates to a composite textile, a composite textile pocket and a method of manufacturing a composite part from such a composite textile and / or from such a composite textile pocket.

L'invention trouve une application notamment à chaque fois que l'on désire fabriquer une pièce composite ayant une bonne résistance mécanique pour un faible poids.The invention finds an application in particular whenever it is desired to manufacture a composite part having good mechanical strength for a low weight.

On connaît déjà des procédés de fabrication de pièces composites. Généralement, ceux-ci consistent en une succession d'étapes lourdes en main d'oeuvre et en coûts. Ainsi, de tels procédés de fabrication connus consistent en la succession d'étapes suivantes :

  • . injection dans un moule d'un pain de mousse de polyuréthanne et généralement d'un agent de démoulage ;
  • . ébavurage de ce pain de mousse de polyuréthanne ;
  • . Dérochage, c'est-à-dire sablage de surface pour enlever l'agent de démoulage et préparer la surface du pain de mousse de polyuréthanne pour permettre l'accrochage mécanique de la résine d'enrobage ;
  • . découpe d'un non tissé de fibres de verre ;
  • . préformage mécanique ou thermique de cette découpe ou revêtement à la main ;
  • . agrafage ou soudage à chaud ;
  • . pose du voile de finition ;
  • . enfin, injection de la résine.
Processes for manufacturing composite parts are already known. Generally, these consist of a succession of steps heavy in manpower and costs. Thus, such known manufacturing methods consist of the following succession of steps:
  • . injection into a mold of a polyurethane foam bar and generally of a release agent;
  • . deburring of this polyurethane foam bread;
  • . Removal, that is to say surface sanding to remove the release agent and prepare the surface of the polyurethane foam bread to allow mechanical attachment of the coating resin;
  • . cutting a nonwoven of glass fibers;
  • . mechanical or thermal preforming of this cut or coating by hand;
  • . stapling or hot welding;
  • . installation of the finishing veil;
  • . finally, injection of the resin.

Comme mentionné ci-dessus, de tels procédés de fabrication connus de l'état de la technique nécessitent un main d'oeuvre abondante et génère des coûts de production importants.As mentioned above, such manufacturing methods known from the prior art require abundant labor and generate significant production costs.

En outre, lors de ce type de procédé, la manutention du pain de mousse de polyuréthanne enrobé du non tissé de fibres de verre est rendue très difficile compte tenu que ce dernier est associé au pain par simple agrafage.In addition, during this type of process, the handling of the polyurethane foam bread coated with the glass fiber nonwoven is made very difficult given that the latter is associated with bread by simple stapling.

A cet effet, l'invention a pour objet de proposer un procédé de fabrication de pièces composites qui pallient les inconvénients ou limites de ceux connus de la technique.To this end, the object of the invention is to propose a method of manufacturing composite parts which overcomes the drawbacks or limits of those known in the art.

Un autre objet de la présente invention est de proposer un textile composite et une poche de textile composite dont l'utilisation dans le procédé de fabrication des pièces composites selon l'invention permet de réduire grandement le nombre d'étapes du procédé et, par là même, d'accélérer la fabrication.Another object of the present invention is to provide a composite textile and a pocket of composite textile whose use in the process for manufacturing the composite parts according to the invention makes it possible to greatly reduce the number of steps in the process and, thereby even, to speed up manufacturing.

Pour ce faire, l'invention propose tout d'abord un textile composite, destiné notamment à être enduit d'une résine d'enrobage, caractérisé en ce qu'il comprend un film extensible comportant une face recto et une face verso, la face recto étant recouverte sensiblement sur toute sa longueur successivement d'au moins un feutre de fibres de verre préformable agglomérées par un liant thermoplastique et d'au moins un voile de non tissé de fibres de verre.To do this, the invention firstly proposes a composite textile, intended in particular to be coated with a coating resin, characterized in that it comprises an extensible film comprising a front face and a back face, the face front being covered substantially over its entire length successively with at least one felt of preformable glass fibers agglomerated by a thermoplastic binder and at least one nonwoven veil of glass fibers.

L'invention propose également une poche de textile composite destinée notamment à être enduite d'une résine d'enrobage, caractérisée en ce qu'elle est constituée de deux textiles composites solidarisés entre eux par la face verso du film extensible selon une ligne de solidarisation.The invention also provides a pocket of composite textile intended in particular to be coated with a coating resin, characterized in that it consists of two composite textiles secured to each other by the back side of the extensible film along a joining line .

L'invention propose enfin un procédé de fabrication d'une pièce composite caractérisé en ce qu'il comprend les étapes successives consistant à :

  • . fabriquer un textile composite en disposant successivement sur un plan de travail le film extensible, au moins le feutre de fibres de verre préformable agglomérées par un liant thermoplastique et au moins le voile de non tissé de fibres de verre, en chauffant le textile composite ainsi obtenu puis en le refroidissant ;
  • . fabriquer une poche de textile composite en superposant deux textiles composites par leur face verso de film puis en les solidarisant selon une ligne de solidarisation en rapport avec la forme de la pièce que l'on cherche à fabriquer ;
  • . effectuer une découpe des textiles composites en périphérie de la ligne de solidarisation ;
  • . disposer la poche de textile composite ainsi obtenue dans un moule de manière à ce qu'elle soit contenue dans le moule mais non maintenue ;
  • . injecter une matière polymérisable dans ladite poche de textile composite ;
  • . refroidir ladite poche ainsi remplie pour obtenir une pièce composite prête à subir une injection de résine d'enrobage ;
  • . et/ou injecter une résine d'enroubage dans ledit moule.
The invention finally proposes a method for manufacturing a composite part, characterized in that it comprises the successive stages consisting in:
  • . fabricating a composite textile by successively placing on the work surface the extensible film, at least the felt of preformable glass fibers agglomerated by a thermoplastic binder and at least the non-woven veil of glass fibers, by heating the composite textile thus obtained then by cooling it;
  • . make a composite textile pocket out of superimposing two composite textiles by their back side of film and then joining them together along a joining line in relation to the shape of the part that one seeks to manufacture;
  • . cut the composite textiles around the periphery of the joining line;
  • . placing the pocket of composite textile thus obtained in a mold so that it is contained in the mold but not maintained;
  • . injecting a polymerizable material into said pocket of composite textile;
  • . cooling said pocket thus filled to obtain a composite part ready to undergo an injection of coating resin;
  • . and / or inject a coating resin into said mold.

Ainsi, il ressort que l'invention permet, par l'utilisation d'un textile composite d'une structure particulière et d'une poche réalisée à partir de ce textile composite, la fabrication aisée, fiable et économique de tout type de pièce composite.Thus, it appears that the invention allows, by the use of a composite textile of a particular structure and a pocket made from this composite textile, the easy, reliable and economical manufacture of any type of composite part. .

D'autres caractéristiques et avantages de l'invention seront bien compris à la lecture de la description qui suit en référence aux dessins annexés dans lesquels :

  • . La figure 1 est une vue schématique en coupe d'un textile composite conforme à la présente invention ;
  • . La figure 2 est une vue schématique en coupe d'une poche de textile composite conforme à la présente invention.
Other characteristics and advantages of the invention will be clearly understood on reading the description which follows with reference to the appended drawings in which:
  • . Figure 1 is a schematic sectional view of a composite textile according to the present invention;
  • . Figure 2 is a schematic sectional view of a pocket of composite fabric according to the present invention.

L'invention concerne donc le domaine des pièces composites. De telles pièces trouvent leur application à chaque fois que l'on désire des pièces ayant une bonne résistance mécanique pour un poids faible. Ces pièces sont généralement destinées à être enduites d'une résine d'enrobage, puis éventuellement, de laque, vernis, peinture ou équivalent.The invention therefore relates to the field of composite parts. Such parts find their application whenever one wishes parts having good mechanical strength for a low weight. These parts are generally intended to be coated with a resin coating, then possibly, lacquer, varnish, paint or equivalent.

Un exemple typique de l'utilisation de telles pièces peut se trouver dans le domaine de l'industrie automobile : il s'agit d'ailerons de voiture.A typical example of the use of such parts can be found in the field of the automotive industry: these are car fins.

L'invention concerne donc tout d'abord un textile composite 1 caractérisé en ce qu'il comprend un film 2 extensible comportant une face recto 2a et une face verso 2b, la face recto 2a étant recouverte sensiblement sur toute sa longueur successivement d'au moins un feutre 3 de fibres de verre préformable agglomérées par un liant thermoplastique et d'au moins un voile 4 de non tissé de fibres de verre.The invention therefore relates first of all to a composite textile 1 characterized in that it comprises an extensible film 2 comprising a front side 2a and a back side 2b, the front side 2a being covered substantially over its entire length successively at least at least one felt 3 of preformable glass fibers agglomerated by a thermoplastic binder and at least one veil 4 of nonwoven of glass fibers.

Ce textile composite permet la réalisation d'une poche qui, selon l'invention est constituée de deux textiles composites 1 solidarisés entre eux par la face verso 2b du film 2 extensible selon une ligne de solidarisation 6.This composite textile allows the production of a pocket which, according to the invention consists of two composite textiles 1 secured to each other by the back side 2b of the film 2 which can be extended along a joining line 6.

Cette poche, comme nous le verrons ci-dessous est destinée à être remplie d'une matière polymérisable, puis enduite d'une résine d'enrobage.This pocket, as we will see below, is intended to be filled with a polymerizable material, then coated with a coating resin.

Chacun des composants du textile composite a été choisi pour faciliter la mise en oeuvre du procédé de fabrication qui sera décrit ci-dessous.Each of the components of the composite textile was chosen to facilitate the implementation of the manufacturing process which will be described below.

Le voile 4, constitué d'un non tissé de fibres de verre extrêmement compactés, a comme première fonction celle de finition. En jouant le rôle de barrière mécanique, il évite aux fibres de verre grossières du feutre 3 d'apparaître à la surface de la pièce composite fabriquée à partir du textile composite. Il améliore donc l'aspect de fini de la surface de la pièce composite qui recevra par la suite la résine d'enrobage. Dès lors, il convient bien évidemment que ce voile 4 de non tissé et de fibres de verre puisse résister aux conditions d'injection de la résine d'enrobage.The veil 4, consisting of a nonwoven of extremely compacted glass fibers, has as its first function that of finishing. By playing the role of mechanical barrier, it prevents the coarse glass fibers of the felt 3 from appearing on the surface of the composite part made from the composite textile. It therefore improves the finish appearance of the surface of the composite part which will subsequently receive the coating resin. Consequently, it is obviously necessary for this veil 4 of nonwoven and of glass fibers to be able to withstand the conditions of injection of the coating resin.

Le feutre 3 de fibres de verre est préformable, ce qui permet d'utiliser, au moment du moulage proprement dit, un renfort qui soit déjà à la forme de la pièce à fabriquer.The felt 3 of glass fibers is preformable, which makes it possible to use, at the time of the actual molding, a reinforcement which is already in the shape of the part to be manufactured.

Le feutre 3 de fibres de verre est également aggloméré par un liant thermoplastique, ce qui permet d'une part son association au film 2 extensible et d'autre part, d'améliorer l'aptitude au préformage du feutre 3.The felt 3 of glass fibers is also agglomerated by a thermoplastic binder, which allows on the one hand its association with the extensible film 2 and on the other hand, improves the preformability of the felt 3.

Ce feutre 3 peut être constitué de plusieurs couches de fibres de verre de titres différentes. Ainsi, à titre indicatif, le feutre 3 peut être constitué d'une couche de fils de 50 tex prise en sandwich entre deux couches de fils de 25 tex.This felt 3 can be made up of several layers of glass fibers of different titles. Thus, by way of indication, the felt 3 may consist of a layer of 50 tex threads sandwiched between two layers of 25 tex threads.

Le feutre 3 de fibres de verre peut également comprendre un insert métallique comme par exemple des broches électriques, un insert plastique ou composite.The felt 3 of glass fibers can also comprise a metallic insert such as for example electric pins, a plastic or composite insert.

La nature et l'épaisseur du film 2 composant en partie le textile composite selon l'invention sont choisies de manière à remplir le cahier des charges suivants :

  • . il doit présenter une adhérence par rapport à la résine d'enrobage et au feutre 3 de fibres de verre ;
  • . il doit présenter une adhérence par rapport à la matière polymérisable avec laquelle il sera mis en contact lors de la fabrication de la pièce composite ;
  • . il doit être étanche à cette même matière polymérisable ;
  • . il doit être extensible compte tenu du fait que, lors de l'injection de la matière polymérisable, le textile composite passera d'une forme à deux dimensions à une forme à trois dimensions ;
  • . enfin, il doit pouvoir être lié par chauffage ou par des moyens physico-chimiques.
The nature and the thickness of the film 2 partially composing the composite textile according to the invention are chosen so as to fulfill the following specifications:
  • . it must have adhesion with respect to the coating resin and to the felt 3 of glass fibers;
  • . it must have an adhesion with respect to the polymerizable material with which it will be brought into contact during the manufacture of the composite part;
  • . it must be impervious to the same polymerizable material;
  • . it must be extensible taking into account that, during the injection of the polymerizable material, the composite textile will pass from a two-dimensional shape to a three-dimensional shape;
  • . finally, it must be able to be bonded by heating or by physico-chemical means.

A cet effet, selon l'invention, le film 2 est thermoplastique. Il présente une épaisseur entre 25 µm et environ 1 mm, de préférence de l'ordre de 50 µm et peut être multicouche.To this end, according to the invention, the film 2 is thermoplastic. It has a thickness between 25 μm and approximately 1 mm, preferably of the order of 50 μm and can be multilayer.

Dans une variante préférée de l'invention, le film 2 est composé de polyesteruréthanne. Mais il peut être également à base de polyétheruréthanne ou de polyamide, l'essentiel étant qu'il remplisse le cahier des charges défini ci-dessus.In a preferred variant of the invention, the film 2 is composed of polyesterurethane. However, it can also be based on polyetherurethane or polyamide, the main thing being that it fulfills the specifications defined above.

Ce textile composite 1, est destiné à être utilisé sous forme de poche 5 qui, lors du procédé de fabrication de la pièce composite, sera rempli d'une matière polymérisable.This composite textile 1 is intended to be used in the form of a pocket 5 which, during the process for manufacturing the composite part, will be filled with a polymerizable material.

Dans une variante préféré de l'invention, cette matière polymérisable est une mousse de polyuréthanne d'une densité comprise entre 0,1 et 0,9 g/cm³ et, de préférence entre 0,3 et 0,4 g/cm³. Mais selon l'usage que l'on veut faire de la pièce composite, cette matière polymérisable peut être de tout type comme, notamment, du polychlorure de vinyle (PVC).In a preferred variant of the invention, this polymerizable material is a polyurethane foam with a density of between 0.1 and 0.9 g / cm³ and, preferably, between 0.3 and 0.4 g / cm³. However, depending on the use to be made of the composite part, this polymerizable material can be of any type such as, in particular, polyvinyl chloride (PVC).

Egalement, en fonction de l'utilisation finale de la pièce composite, la formulation de la mousse de polyuréthanne peut être adaptée pour avoir un effet de peau, c'est-à-dire avoir une densité importante en surface et une densité plus faible au coeur.Also, depending on the end use of the composite part, the formulation of the polyurethane foam can be adapted to have a skin effect, that is to say to have a high density on the surface and a lower density at the heart.

La matière polymérisable peut comprendre également un insert métallique, plastique ou composite et elle peut être chargée par exemple de microbilles de verre ou de céramique ou de microfibres de verre.The polymerizable material can also comprise a metallic, plastic or composite insert and it can be loaded for example with glass or ceramic microbeads or glass microfibers.

L'invention concerne également un procédé de fabrication d'une pièce composite comprenant essentiellement cinq étapes :

  • a) une étape de fabrication du textile composite 1 ;
  • b) une étape de fabrication d'une poche 5 de textile composite ;
  • c) une étape de préparation de la poche de textile composite en vue de l'injection de la matière polymérisable ;
  • d) une étape d'injection de la matière polymérisable dans ladite poche 5 ;
  • e) une étape d'injection d'une résine d'enrobage.
The invention also relates to a method of manufacturing a composite part essentially comprising five steps:
  • a) a step of manufacturing the composite textile 1;
  • b) a step of manufacturing a pocket 5 of composite textile;
  • c) a step of preparing the pocket of composite textile for the injection of the polymerizable material;
  • d) a step of injecting the polymerizable material into said pocket 5;
  • e) a step of injecting a coating resin.

a) FABRICATION DU TEXTILE COMPOSITE 1 :a) MANUFACTURE OF COMPOSITE TEXTILE 1:

Le textile composite 1 selon l'invention est fabriqué en disposant successivement sur un plan de travail (qui peut être éventuellement un moule) le film 2 extensible, au moins le feutre 3 de fibres de verre préformable agglomérées par un liant thermoplastique et au moins le voile 4 de non tissé de fibres de verre.The composite textile 1 according to the invention is manufactured by successively placing on a work surface (which may possibly be a mold) the extensible film 2, at least the felt 3 of preformable glass fibers agglomerated by a thermoplastic binder and at least the veil 4 of glass fiber nonwoven.

Le voile 4 de non tissé de fibres de verre peut être disposé, non pas à cette étape, mais au moment de l'étape de fabrication de la poche 5 de textile composite.The veil 4 of non-woven glass fibers can be placed, not at this stage, but at the time of the stage of manufacturing the pocket 5 of composite textile.

Le textile composite 1 est ensuite chauffé par passage dans un four (radiant, à air chaud, etc.) à une température comprise entre 80 et 110°C. Ce chauffage permet d'une part au liant thermoplastique du feutre 3 d'agir, et, d'autre part, au film 2 thermoplastique de se ramollir, le résultat de ce chauffage étant l'association intime du voile 4 de non tissé de fibres de verre, du feutre 3 de fibres de verre et du film 2 thermoplastique.The composite fabric 1 is then heated by passage through an oven (radiant, hot air, etc.) to a temperature between 80 and 110 ° C. This heating allows on the one hand the thermoplastic binder of the felt 3 to act, and, on the other hand, the thermoplastic film 2 to soften, the result of this heating being the intimate association of the web 4 of nonwoven fibers of glass, of the felt 3 of glass fibers and of the thermoplastic film 2.

A la suite de ce chauffage, le textile composite 1 peut être refroidi et stocké.Following this heating, the composite textile 1 can be cooled and stored.

b) FABRICATION DE LA POCHE 5 DE TEXTILE COMPOSITE :b) MANUFACTURE OF COMPOSITE TEXTILE POCKET 5:

Cette étape consiste à superposer deux textiles composites 1 obtenus à l'étape précédente, par leurs faces verso 2b de film 2, puis à les solidariser selon une ligne de solidarisation 6 en rapport avec la forme de la pièce composite que l'on cherche à fabriquer.This step consists in superimposing two composite textiles 1 obtained in the previous step, by their back sides 2b of film 2, then in joining them together along a joining line 6 in relation to the shape of the composite part that is to be sought. to manufacture.

Cette solidarisation des deux textiles composites 1 est réalisée par des moyens de soudure (chauffage, haute fréquence, ultrasons) ou par des moyens de collage (colle polyuréthanne, silicone, mastic).This joining of the two composite textiles 1 is carried out by welding means (heating, high frequency, ultrasound) or by bonding means (polyurethane glue, silicone, mastic).

Simultanément ou non à l'étape de solidarisation, on effectue alors une découpe des textiles composites 1 en périphérie de la ligne de solidarisation 6. Cette découpe est effectuée à une distance de l'ordre de 2 à 3 cm de la ligne de solidarisation 6.Simultaneously or not at the joining step, a composite textiles 1 is then cut at the periphery of the joining line 6. This cutting is carried out at a distance of the order of 2 to 3 cm from the joining line 6 .

Par ailleurs, en plus de l'introduction de la matière polymérisable dans la poche 5 de textile composite et en vue de l'évacuation du gaz suite à cette injection, il est prévu deux variantes de réalisation dans la procédé de fabrication conforme à la présente invention :

  • . Avant les étapes de solidarisation et de découpe, on positionne des canules d'injection de manière à ce qu'elles soient à cheval sur la ligne de solidarisation 6 lors de l'étape de solidarisation pour permettre ainsi leur emprisonnement ;
  • . Ou bien, lors de l'étape de solidarisation, on laisse des réserves non solidarisées destinées à recevoir lesdites canules d'injection.
Furthermore, in addition to the introduction of the polymerizable material into the pocket 5 of composite textile and for the evacuation of the gas following this injection, there are provided two alternative embodiments in the manufacturing process according to the present invention:
  • . Before the joining and cutting steps, injection cannulas are positioned so that they are astride the joining line 6 during the joining step to thereby allow their imprisonment;
  • . Or, during the joining step, non-joined reserves are left intended to receive said injection cannulas.

c) PREPARATION DE LA POCHE 5 DE TEXTILE COMPOSITE :c) PREPARATION OF THE COMPOSITE TEXTILE POCKET 5:

Cette étape consiste à disposer la poche 5 de textile composite obtenue par l'étape précédente dans un moule de manière à ce qu'elle soit contenue dans le moule mais non maintenue. Ce moule peut être constitué de plusieurs parties mobiles ou amovibles permettant de faciliter et d'assurer un bon placement de la poche 5, lesdites parties étant rabattues avant ou pendant l'injection de la matière polymérisable.This step consists in placing the pocket 5 of composite textile obtained by the previous step in a mold so that it is contained in the mold but not maintained. This mold can be made up of several movable or removable parts making it possible to facilitate and ensure proper placement of the bag 5, said parts being folded down before or during the injection of the polymerizable material.

Egalement, lors de cette étape on rabat la périphérie flottante 7 de la poche 5 de textile de composite vers le centre de ladite poche.Also, during this step, the floating periphery 7 of the pocket 5 of composite textile is folded towards the center of said pocket.

d) INJECTION DE LA MATIERE POLYMERISABLE :d) INJECTION OF THE POLYMERIZABLE MATERIAL:

Avant l'injection proprement dit de la matière polymérisable, on effectue tout d'abord une dépressurisation de la poche 5 de textile composite pour la plaquer contre le moule. Puis, après injection, on fait le vide dans le moule pour aider à l'extension de la matière polymérisable et pour qu'elle prenne toute la forme de l'empreinte du moule.Before the actual injection of the material polymerizable, first of all a depressurization of the pocket 5 of composite textile is carried out to press it against the mold. Then, after injection, a vacuum is made in the mold to help the extension of the polymerizable material and so that it takes all the shape of the mold imprint.

Lors de ces étapes, on travaille avec des moules chauffés à une température comprise entre 50 et 80°C de manière à lancer la réaction de polymérisation de la matière polymérisable et à favoriser l'effet de thermoformage des fibres de verre du feutre 3 et du voile 4.During these steps, we work with molds heated to a temperature between 50 and 80 ° C so as to initiate the polymerization reaction of the polymerizable material and to promote the thermoforming effect of the glass fibers of the felt 3 and of the veil 4.

Il est d'ailleurs conseillé d'utiliser des moules métalliques compte tenu de cette température d'utilisation et de l'effet abrasif des fibres de verre.It is also advisable to use metal molds taking into account this temperature of use and the abrasive effect of the glass fibers.

Après cette étape, une coupure des carottes de matière polymérisable peut éventuellement être nécessaire.After this step, cutting the cores of polymerizable material may possibly be necessary.

Après refroidissement, on obtient une pièce composite prête à subir une injection de résine d'enrobage.After cooling, a composite part is obtained ready to undergo an injection of coating resin.

e) INJECTION DE LA RESINE D'ENROBAGEe) INJECTION OF THE COATING RESIN

Selon une variante du procédé conforme à l'invention, on peut injecter une résine d'enrobage directement après l'injection de matière polymérisable et donc avant le refroidissement mentionné ci-dessus. A cet effet, on coupe la carotte d'injection résiduelle de l'injection de matière polymérisable, sans retirer la pièce du moule, puis on injecte la résine d'enrobage dans le feutre 3 de fibres de verre. Cette injection se fait à une température de 80°C sous une pression de 30 bars. Après polymérisation, on obtient une pièce composite finie, c'est-à-dire enrobée de résine. Bien évidemment, le moule et la matière polymérisable doivent pouvoir résister à une pression de 30 bars.According to a variant of the process according to the invention, a coating resin can be injected directly after the injection of polymerizable material and therefore before the cooling mentioned above. To this end, the residual injection core is cut from the injection of polymerizable material, without removing the part from the mold, then the coating resin is injected into the felt 3 of glass fibers. This injection is carried out at a temperature of 80 ° C. under a pressure of 30 bars. After polymerization, a finished composite part is obtained, that is to say coated with resin. Obviously, the mold and the polymerizable material must be able to withstand a pressure of 30 bars.

La présente invention sera maintenant illustrée à l'aide d'un exemple donné à titre indicatif et non limitatif d'une fabrication d'un aileron de véhicule automobile :

  • . Voile de non tissé de fibres de verre
  • . Feutre de fibres de verre : MAT UNIFILO U 750 commercialisé par la société VETROTEX
       Masse surfacique : 375 g/m²
  • . Film thermoplastique : WALOPUR 2201 AU commercialisé par la société WOLFF WALSRODE
       Densité : 1,14 g/cm3
       Plage de ramollissement : 145 - 155°C
       Dureté shore A : 85
       Epaisseur : 25 µm
       Mousse de polyuréthanne : ELASTOLIT (marque déposée) ED 9031/1 commercialisée par la société ELASTOGRAN.
The present invention will now be illustrated in using an example given as an indication and not limiting of a manufacture of a motor vehicle spoiler:
  • . Glass fiber nonwoven veil
  • . Glass fiber felt: MAT UNIFILO U 750 sold by the company VETROTEX
    Area weight: 375 g / m²
  • . Thermoplastic film: WALOPUR 2201 AU sold by the company WOLFF WALSRODE
    Density: 1.14 g / cm3
    Softening range: 145 - 155 ° C
    Shore A hardness: 85
    Thickness: 25 µm
    Polyurethane foam: ELASTOLIT (registered trademark) ED 9031/1 sold by the company ELASTOGRAN.

Claims (30)

Textile composite (1) destiné notamment à être enduit d'une résine d'enrobage, caractérisé par le fait qu'il comprend un film (2) extensible comportant une face recto (2a) et une face verso (2b), la face recto (2a) étant recouverte sensiblement sur toute sa longueur, successivement d'au moins un feutre (3) de fibres de verre préformable agglomérées par un liant thermoplastique et d'au moins un voile (4) de non tissé de fibres de verre.Composite textile (1) intended in particular to be coated with a coating resin, characterized in that it comprises an extensible film (2) comprising a front side (2a) and a back side (2b), the front side (2a) being covered substantially over its entire length, successively with at least one felt (3) of preformable glass fibers agglomerated by a thermoplastic binder and at least one veil (4) of nonwoven of glass fibers. Textile composite selon la revendication 1, caractérisé par le fait que la nature et l'épaisseur du film (2) sont choisies de manière à ce qu'il présente une adhérence par rapport à la résine d'enrobage et au feutre (3) de fibres de verre.Composite textile according to claim 1, characterized in that the nature and the thickness of the film (2) are chosen so that it has adhesion with respect to the coating resin and to the felt (3) of glass fibers. Textile composite selon la revendication 1 ou 2, caractérisé par le fait que le film (2) est thermoplastique.Composite textile according to claim 1 or 2, characterized in that the film (2) is thermoplastic. Textile composite selon l'une quelconque des revendications 1 à 3, caractérisé par le fait que le film (2) a une épaisseur comprise entre 25 µm et environ 1 mm, de préférence de l'ordre de 50 µm.Composite textile according to any one of claims 1 to 3, characterized in that the film (2) has a thickness of between 25 µm and approximately 1 mm, preferably of the order of 50 µm. Textile composite selon l'une quelconque des revendications 1 à 4, caractérisé par le fait que le film (2) est multicouche.Composite textile according to any one of claims 1 to 4, characterized in that the film (2) is multilayer. Textile composite selon l'une quelconque des revendications 1 à 5, caractérisé par le fait que le film (2) est composé de polyesteruréthanne, de polyétheruréthanne ou de polyamide.Composite textile according to any one of claims 1 to 5, characterized in that the film (2) is composed of polyesterurethane, polyetherurethane or polyamide. Textile composite selon l'une quelconque des revendications 1 à 6, caractérisé par le fait que le feutre (3) est constitué de plusieurs couches de fibres de verre de titres différents.Composite textile according to any one of claims 1 to 6, characterized in that the felt (3) consists of several layers of glass fibers of different titles. Textile composite selon l'une quelconque des revendications 1 à 7, caractérisé par le fait que le feutre (3) comprend un insert métallique, plastique ou composite.Composite textile according to any one of Claims 1 to 7, characterized in that the felt (3) comprises a metallic, plastic or composite insert. Poche (5) de textile composite destinée notamment à être enduite d'une résine d'enrobage, caractérisée par le fait qu'elle est constituée de deux textiles composites (1) selon l'une quelconque des revendications 1 à 8 solidarisés entre eux par la face verso (2b) du film (2) extensible selon une ligne de solidarisation (6).Pouch (5) of composite textile intended in particular to be coated with a coating resin, characterized in that it consists of two composite textiles (1) according to any one of claims 1 to 8 secured to each other by the reverse side (2b) of the film (2) extendable along a joining line (6). Poche (5) de textile composite selon la revendication 9, caractérisée par le fait qu'elle est remplie d'une matière polymérisable.Pouch (5) of composite textile according to claim 9, characterized in that it is filled with a polymerizable material. Poche (5) de textile composite selon la revendication 10, caractérisée par le fait que la matière polymérisable est une mousse de polyuréthanne.Pouch (5) of composite textile according to claim 10, characterized in that the polymerizable material is a polyurethane foam. Poche (5) de textile composite selon la revendication 11, caractérisée par le fait que la formulation de la mousse de polyuréthanne est adaptée pour avoir un effet de peau.Pouch (5) of composite textile according to claim 11, characterized in that the formulation of the polyurethane foam is adapted to have a skin effect. Poche (5) de textile composite selon l'une quelconque des revendications 10 à 12, caractérisée par le fait que la matière polymérisable comprend un insert métallique, plastique ou composite.Composite textile bag (5) according to any one of Claims 10 to 12, characterized in that the polymerizable material comprises a metallic, plastic or composite insert. Poche (5) de textile composite selon l'une quelconque des revendications 10 à 13, caractérisée par le fait que la matière polymérisable est chargée.Pouch (5) of composite textile according to any one of claims 10 to 13, characterized in that the polymerizable material is loaded. Procédé de fabrication d'une pièce composite, caractérisé par le fait qu'il comprend les étapes successives consistant à : . fabriquer un textile composite (1) selon l'une quelconque des revendications 1 à 8 en disposant successivement sur un plan de travail le film (2) extensible, au moins le feutre (3) de fibres de verre préformable agglomérées par un liant thermoplastique et au moins le voile (4) de non tissé de fibres de verre, en chauffant le textile composite (1) ainsi obtenu puis en le refroidissant ; . fabriquer une poche (5) de textile composite en superposant deux textiles composites (1) par leur face verso (2b) de film (2) puis en les solidarisant selon une ligne de solidarisation (6) en rapport avec la forme de la pièce que l'on cherche à fabriquer ; . effectuer une découpe des textiles composites (1) en périphérie de la ligne de solidarisation (6) ; . disposer la poche (5) de textile composite ainsi obtenue dans un moule de manière à ce qu'elle soit contenue dans le moule mais non maintenue ; . injecter une matière polymérisable dans ladite poche (5) de textile composite ; . refroidir ladite poche (5) ainsi remplie pour obtenir une pièce composite prête à subir une injection de résine d'enrobage ; . et/ou injecter une résine d'enrobage dans ledit moule. Method for manufacturing a composite part, characterized in that it comprises the successive stages consisting in: . manufacturing a composite textile (1) according to any one of claims 1 to 8 by successively placing on a work surface the extensible film (2), at least the felt (3) of preformable glass fibers agglomerated by a thermoplastic binder and at least the veil (4) of non-woven glass fibers, by heating the composite textile (1) thus obtained then by cooling it; . fabricate a pocket (5) of composite textile superimposing two composite textiles (1) by their back side (2b) of film (2) then by joining them together along a joining line (6) in relation to the shape of the part that one is seeking to manufacture; . cutting the composite textiles (1) around the periphery of the joining line (6); . placing the pocket (5) of composite textile thus obtained in a mold so that it is contained in the mold but not maintained; . injecting a polymerizable material into said pocket (5) of composite textile; . cooling said pocket (5) thus filled to obtain a composite part ready to undergo an injection of coating resin; . and / or injecting a coating resin into said mold. Procédé selon la revendication 15, caractérisé par le fait que l'on chauffe le textile composite (1) à une température comprise entre 8O°C et 110°C lors de sa fabrication.Method according to claim 15, characterized in that the composite textile (1) is heated to a temperature between 80 ° C and 110 ° C during its manufacture. Procédé selon la revendication 15 ou 16, caractérisé par le fait que l'on stocke le textile composite (1) avant la fabrication de la poche (5).Method according to claim 15 or 16, characterized in that the composite textile (1) is stored before the production of the pocket (5). Procédé selon l'une quelconque des revendications 15 à 17, caractérisé par le fait que lors de la fabrication de la poche (5), le solidarisation des deux textiles composites (1) est réalisée par des moyens de soudure, de collage ou équivalent.Method according to any one of claims 15 to 17, characterized in that during the production of the pocket (5), the two composite textiles (1) are joined together by means of welding, gluing or the like. Procédé selon l'une quelconque des revendications 15 à 18, caractérisé par le fait que les étapes de solidarisation et de découpe ont lieu simultanément.Method according to any one of Claims 15 to 18, characterized in that the joining and cutting steps take place simultaneously. Procédé selon l'une quelconque des revendications 15 à 19, caractérisé par le fait que la découpe est effectuée à une distance de l'ordre de 2 à 3 cm de la ligne de solidarisation.Process according to any one of Claims 15 to 19, characterized in that the cutting is carried out at a distance of the order of 2 to 3 cm from the joining line. Procédé selon l'une quelconque des revendications 15 à 20, caractérisé par le fait qu'avant les étapes de solidarisation et de découpe, on positionne des canules d'injection de manière à ce qu'elles soient à cheval sur la ligne de solidarisation (6) lors de l'étape de solidarisation et ainsi être emprisonnées.Method according to any one of claims 15 to 20, characterized in that before the joining and cutting steps, injection cannulas are positioned so that they are astride the joining line ( 6) during the joining stage and thus be imprisoned. Procédé selon l'une quelconque des revendications 15 à 20, caractérisé par le fait que lors de l'étape de solidarisation, on laisse des réserves non solidarisées destinées à recevoir des canules d'injection.A method according to any one of claims 15 to 20, characterized in that during the joining step, leaving unconnected reserves intended to receive injection cannulas. Procédé selon l'une quelconque des revendications 15 à 22, caractérisé par le fait que l'étape d'injection de la matière polymérisable est précédée d'une étape de dépressurisation de la poche (5) de textile composite.Process according to any one of Claims 15 to 22, characterized in that the step of injecting the polymerizable material is preceded by a step of depressurizing the pocket (5) of composite textile. Procédé selon l'une quelconque des revendications 15 à 23, caractérisé par le fait qu'on fait le vide dans le moule après l'injection de la matière polymérisable pour aider à son expansion.Process according to any one of Claims 15 to 23, characterized in that a vacuum is made in the mold after the injection of the polymerizable material to aid in its expansion. Procédé selon l'une quelconque des revendications 15 à 24, caractérisé par le fait qu'on travaille avec des moules chauffés à une température comprise entre 50 et 80°C.Process according to any one of Claims 15 to 24, characterized in that it works with molds heated to a temperature between 50 and 80 ° C. Procédé selon l'une quelconque des revendications 15 à 25, caractérisé par le fait que la matière polymérisable est une mousse de polyuréthanne.Process according to any one of Claims 15 to 25, characterized in that the polymerizable material is a polyurethane foam. Procédé selon la revendication 26, caractérisé par le fait que la formulation de la mousse de polyuréthanne est adaptée pour avoir un effet de peau.Method according to claim 26, characterized in that the formulation of the polyurethane foam is adapted to have a skin effect. Procédé selon l'une des revendication 26 ou 27, caractérisé par le fait que la matière polymérisable comprend un insert métallique, plastique ou composite.Method according to one of claims 26 or 27, characterized in that the polymerizable material comprises a metallic, plastic or composite insert. Procédé selon l'une quelconque des revendications 26 à 28, caractérisé par le fait que la matière polymérisable est chargée.Method according to any one of Claims 26 to 28, characterized in that the polymerizable material is charged. Procédé selon l'une quelconque des revendications 15 à 29, caractérisé par le fait qu'on utilise un moule comportant des parties mobiles ou amovibles.Process according to any one of Claims 15 to 29, characterized in that a mold is used which has movable or removable parts.
EP95402095A 1994-09-16 1995-09-18 Textile composite, textile composite pocket and method of producing a composite part from such a textile or pocket Withdrawn EP0703307A1 (en)

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FR9411084A FR2724667B1 (en) 1994-09-16 1994-09-16 COMPOSITE TEXTILE, COMPOSITE TEXTILE POCKET AND METHOD FOR MANUFACTURING A COMPOSITE PIECE FROM SUCH A TEXTILE OR SUCH A POCKET
FR9411084 1994-09-16

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US7833462B2 (en) 2003-05-08 2010-11-16 Ecim Technologies B.V. Method and apparatus for manufacturing vehicle parts
EP2278053A3 (en) * 2003-05-08 2011-05-25 ECIM Technologies B.V. Method and apparatus for manufacturing vehicle parts
EP2309044A3 (en) * 2003-05-08 2011-05-25 ECIM Technologies B.V. Method and apparatus for manufacturing vehicle parts

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FR2724667A1 (en) 1996-03-22

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