EP2635733A1 - Couche de voile présentant des faisceaux contenant des fibres de carbone - Google Patents

Couche de voile présentant des faisceaux contenant des fibres de carbone

Info

Publication number
EP2635733A1
EP2635733A1 EP11782098.5A EP11782098A EP2635733A1 EP 2635733 A1 EP2635733 A1 EP 2635733A1 EP 11782098 A EP11782098 A EP 11782098A EP 2635733 A1 EP2635733 A1 EP 2635733A1
Authority
EP
European Patent Office
Prior art keywords
fibers
pile layer
bundles
pile
carbon fibers
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP11782098.5A
Other languages
German (de)
English (en)
Inventor
Birgit Reiter
Martin Danzer
Joern Boes
Sylvain Bastian
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.)
SGL Automotive Carbon Fibers GmbH and Co KG
Original Assignee
SGL Carbon SE
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 SGL Carbon SE filed Critical SGL Carbon SE
Publication of EP2635733A1 publication Critical patent/EP2635733A1/fr
Withdrawn legal-status Critical Current

Links

Classifications

    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H11/00—Non-woven pile fabrics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/081—Combinations of fibres of continuous or substantial length and short fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/028—Net structure, e.g. spaced apart filaments bonded at the crossing points
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G1/00—Severing continuous filaments or long fibres, e.g. stapling
    • D01G1/02—Severing continuous filaments or long fibres, e.g. stapling to form staple fibres not delivered in strand form
    • D01G1/04—Severing continuous filaments or long fibres, e.g. stapling to form staple fibres not delivered in strand form by cutting
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G13/00—Mixing, e.g. blending, fibres; Mixing non-fibrous materials with fibres
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G15/00—Carding machines or accessories; Card clothing; Burr-crushing or removing arrangements associated with carding or other preliminary-treatment machines
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01G—PRELIMINARY TREATMENT OF FIBRES, e.g. FOR SPINNING
    • D01G7/00—Breaking or opening fibre bales
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/04—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres
    • D04H1/06—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres having existing or potential cohesive properties, e.g. natural fibres, prestretched or fibrillated artificial fibres by treatment to produce shrinking, swelling, crimping or curling of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4209—Inorganic fibres
    • D04H1/4242—Carbon fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4274—Rags; Fabric scraps
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4374—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece using different kinds of webs, e.g. by layering webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/44—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling
    • D04H1/46—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
    • D04H1/498—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
    • D04H1/74—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel (anisotropic fleeces)
    • 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
    • D04H3/045—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 for net manufacturing
    • 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
    • D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
    • D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B11/00—Making preforms
    • B29B11/14—Making preforms characterised by structure or composition
    • B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/20—All layers being fibrous or filamentary
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23929—Edge feature or configured or discontinuous surface
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23957—Particular shape or structure of pile
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23957—Particular shape or structure of pile
    • Y10T428/23964—U-, V-, or W-shaped or continuous strand, filamentary 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23979—Particular backing structure or composition
    • 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
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23907—Pile or nap type surface or component
    • Y10T428/23993—Composition of pile or adhesive

Definitions

  • the present invention relates to a pile layer comprising a plurality of bundles partly broken down into single fibers and comprising carbon fibers, and
  • the present invention relates to a nonwoven fabric comprising such pile layers.
  • Pile layers comprising carbon fibers are particularly well suited as a starting structure for the production of nonwovens or nonwovens, which are used in numerous applications in the automotive industry. Above all, they are used for the production of automotive components.
  • the nonwovens or nonwoven fabrics in question are advantageously processed into light but mechanically very strong fiber composite structures, which are increasingly regarded as a preferred and future-oriented material.
  • individual fibers of a predetermined length distribution are typically fed via suitable feed devices to a pile forming machine.
  • a Florsentemaschine can be performed, for example, as a carding.
  • air-driven, pneumatic or fluid-assisted pile forming machines are known.
  • the individual fibers are entwined with each other, so that a flat structure is formed, which has a sufficient intrinsic stability by the fiber entanglements that can withstand external mechanical effects during further processing.
  • the pile layers taken from the pile forming machines can be processed in further steps to form nonwovens.
  • the pile layers can be transferred, for example, by doubling, ie, by superimposing the pile layers, into a nonwoven having the desired thickness and a suitable total fiber content. Even after solidification, for example by needling, as a nonwoven fabric can be fed to a further processing.
  • Nonwovens differ from ordinary nonwovens, generally because they have undergone chemical, mechanical or thermal consolidation.
  • a pile layer and a fleece. All of these structures are obtained in a process which has the aim of entangling fibers into a mechanically relatively stable planar structure.
  • the nonwoven fabric differs from the nonwoven or the pile layer by a further step of the subsequent solidification, as already described above.
  • the individual fibers supplied to the pile forming machines typically have to be subjected to a complex mechanical treatment.
  • a complex preparation of carbon fibers is required.
  • the carbon fibers can be taken from carbon fiber strands. These must first be taken from a coil and fed to a cutting device. After cutting to a suitable length, the bundles of carbon fibers must be disrupted by separating the carbon fibers in the bundle sections.
  • the fibers prior to feeding into the pile forming machine, the fibers must still be suitably piled up and added in a metered manner to the pile forming process. Only then are the isolated, ie fully digested, fibers added to the pile forming machine in which the fibers can be made into a pile.
  • these processing steps are not only relatively expensive, but also mean a higher maintenance of the devices of the entire process flow.
  • these processing costs will be increased if fiber-reinforced composites based on fiber waste and / or recycled carbon fibers are to be produced. In numerous manufacturing processes of the carbon fiber processing industry numerous cutting waste accumulate, which should be used for further cost savings.
  • waste products also fall within the scope of the textile production process, which can also provide valuable carbon fibers, which are to be used for cost and raw material savings further uses.
  • carbon fiber reinforced plastics which should also be recycled to the recycling cycle in order to enable a closed recyclable material chain.
  • the processing is particularly complex, since several processing steps to open, open and sometimes also clean the fibers are additionally required to obtain isolated fibers. Only after a number of processing steps is it possible to recover fibers which can be fed to processes which are typically carried out with original, ie not yet used carbon fibers.
  • Object of the present invention is to propose a pile layer and a method for producing such a pile layer, which is a simple recycling of recycled materials from materials, in particular car- permit carbon fibers in textile structures suitable for technical applications.
  • a pile layer which also allows the use of recycled carbon fibers, but the suitability of the pile layer for technical applications must not be reduced.
  • a nonwoven or a nonwoven fabric comprising such pile layers.
  • the object which the manufacturing process still has to fulfill is to provide a less expensive process for producing a pile layer compared with the methods known from the prior art.
  • this object is achieved by a pile layer according to claim 1, as well as by a production method according to claim 14.
  • the object of the invention is further achieved with a nonwoven or a nonwoven fabric according to claim 13.
  • the object on which the invention is based is achieved by a pile layer which has a plurality of bundles partially broken down into individual fibers and comprising carbon fibers and foreign substances, wherein the carbon fibers have at least a mass fraction of 70% of the total mass of the pile layer and the foreign substances not more than 30%, but not less than 2%, and the foreign matter is taken from a recycling process.
  • the invention is achieved by a method for producing a pile layer, which comprises the following steps: cutting a sheet-like structure which comprises bundles comprising carbon fibers and is at least partially fixed by foreign substances, in particular by knitting or sewing threads or by a binder; Processing the cut sheet to partially open the bundles in single fibers in an opening device, in particular in a tearing machine; Introducing the batch partially digested by this processing into a pile forming machine, in particular into a carding device; Operating the pile forming machine such that the bundles are not completely singulated into single fibers, but carbon fibers of the bundles are entangled with further fibers; Removing the pile layer from the pile forming machine;
  • the pile layer according to the invention is characterized in an advantageous manner in that it has a foreign substance content of at most 30%, but the carbon fibers have a mass fraction of at least 70%.
  • the proportion of carbon fibers in this case primarily determines the strength and the quality of the pile layer, the proportion of foreign matter contributing a share to the weight per unit area of the entire textile, but without significantly influencing the strength and the quality.
  • the quality and strength particularly relates to the quality and strength that the pile layer can provide to a composite in which it is integrated.
  • the pile layer according to the invention has a plurality of bundles comprising carbon fibers.
  • the bundles typically originate from the textiles which have been recycled to recover the fibers for pile layer production. Accordingly, the recycling process does not require complete development of the fibers in the pile layer production. fray.
  • the textiles are typically carbon fiber-containing textiles, but may also have no carbon fibers depending on the field of application.
  • the process for producing the pile layer according to the invention by means of a pile forming machine can be adjusted so that a dissolution of the introduced bundles in the pile forming machine in individual fibers need not be done.
  • individual fibers are introduced in addition to bundles in the pile forming machine.
  • the bundles may be in an unconsolidated fiber tangle, in which the fibers partially protrude from a bundle and are entangled with other fibers, although other fibers may also be present in the bundle.
  • the fiber content in a bundle may consist entirely of carbon fibers or only in part.
  • the fibers fed to the pile forming machine can also be made partly of original fibers which are not taken from a recycling process.
  • the number of processing steps can be adjusted, for example, or the functional components in the pile forming machine. Also conceivable is a geometrical adaptation of the functional components of the pile forming machine.
  • a bundle in this context, as well as in the context of the present patent application, is to be understood as a collection of fibers which at least partially have a substantially parallel directional course, wherein the fiber density in the bundle is increased at least partially compared to the fiber density of the environment ,
  • bundles can also be very optically identified, since they visually distinguish themselves easily from their surroundings and can be well identified as a bundle.
  • a bundle can also have a cohesion of the individual fibers, which protects the bundle from falling apart into individual fibers during mechanical stressing.
  • An advantage of the pile layer according to the invention is that the bundles are indeed covered by the pile layer, but the fibers are not completely dissolved in individual fibers. This gives the pile layer particular strength, in particular special in the direction of a stress, which takes place in the longitudinal direction of the fibers of the bundles. Thus, the bundles in the direction of their fiber flow outer force effects, which act on the fiber composite to be produced later, absorb much better than compared to isolated and not further aligned fibers.
  • a particularly advantageous embodiment of the pile layer according to the invention is characterized in that the bundles comprising the carbon fibers are at least partly also taken from a recycling process.
  • the bundles, as well as the fibers covered by the pile layer are at least partly taken from a recycling process.
  • This allows the pile layer to be produced particularly inexpensively, since fewer production steps are to be expected.
  • the materials used in the pile layer are sometimes already coordinated.
  • the pile layer to be produced with original, i. carbon fiber not yet used is offset in order to compensate for any possible loss of quality, which result from the recycled carbon fibers.
  • a fraction of new single carbon fibers may be added to a certain minimum length of the pile layer to increase approximately the total fiber length distribution in the pile layer after the recycling process results in a shortening of the carbon fibers in the recycling process.
  • original carbon fiber bundles can also be added to the flame forming process.
  • the foreign substances at least partly comprise foreign fibers which are not carbon fibers.
  • Such foreign fibers are in particular glass fibers and synthetic fibers, such as the chemical textile fibers of polyethylene, polyamide, polyester, polypropylene, etc ..
  • These fibers are introduced into the pile layer during the pile forming process.
  • these fibers preferably engulf with the carbon fibers or the other fibers covered by the pile layer.
  • the foreign fibers contribute only insignificantly to the strength of the pile layer, since the strength is essentially provided by the carbon fibers. This relates in particular to the strength conferring the pile layer to a fiber composite workpiece comprising it. There However, the execution of the pile layer has sufficient carbon fibers, the required minimum strength can continue to be guaranteed.
  • the carbon fibers have a predetermined first arrangement to each other, which determines a first pattern, and the foreign fibers to a second arrangement to each other, which determines a second pattern, the first pattern of the second pattern is different.
  • a pattern is to be understood here and below as a distribution of the material density over the surface to be considered, with material density variations at least partially present. In particular, these material density variations are visually recognizable and can be systematically compared.
  • the distinction between the two patterns can be determined in particular by means of a flat autocorrelation function.
  • a surface portion of the embodiment according to the pile layer for example, a surface section of 15 cm to 15 cm, selected and subdivided into smaller subunits - about 1, 5 mm by 1, 5 mm - the same area.
  • the individual subunit units are assigned a value on a predetermined scale, for example on a scale of -5 to +5.
  • the normalization takes place in relation to the total fiber content in the area considered. Subsequently, for each subunit unit, a two-dimensional integral or a two-dimensional sum over all adjacent subunit units is calculated, the integral or the sum being calculated via a product of the value of the predetermined subunit unit with the values of the adjacent subunit units.
  • the calculation thus takes place in the sense of a correlation of the fiber surface density of the sub-surface units with itself, ie the autocorrelation of the fiber surface density.
  • the value thus determined is assigned to the respectively predetermined sub-surface unit, wherein the calculation must be carried out correspondingly for all other sub-surface units.
  • a two-dimensional weighting function can also be taken into account for simplifying the calculation, which restricts the integration or sum, for example, to an integration or sum over the next 10 neighbors.
  • this number must not be chosen so small that the integration or sum does not extend to possibly repeating patterns of carbon fiber density, which is caused by the appropriate arrangement of the bundles in the pile layer.
  • the results of the individual calculations are normalized again so that they can be made comparable for all sub-surface units.
  • the normalization can also take into account edge effects which can occur with sub-surface units which are close to the edge of the selected and examined surface section of about 15 cm by 15 cm.
  • the values of the autocorrelation function will deviate from zero or another base value which indicates that no repetitive regularities occur. ie the distribution of the values is purely coincidental. The autocorrelation function is therefore able to account for regularities in a pattern. However, these regularities must be different from only a static sequence of values. If the patterns are purely random, i. If these patterns result merely from a purely random distribution of the individual values, the autocorrelation function will yield a base value or zero for all subunit units. The base value depends on the preselected scale values, i. the underlying, which indicates that there is a purely random distribution, also depends on the scale initially chosen.
  • a pattern is different, for example, if the normalized and summed values of all comparable subunit units differ on average by more than 5%.
  • Other mathematically meaningful or technically meaningful distinctions to the deviation of the two arrangements of subunit units or the patterns to be compared are possible. borrowed.
  • the calculation of the mathematical or complex order of a pattern in the surface is suitable for this purpose.
  • the two patterns can also be compared by a simplified approach. This is, as will be explained in detail in the figure part, especially preferred when the impurity density or the foreign fiber density is so low that only a proportion of the subunits of the impurity density or foreign fiber density has an overlap with the subunit units, but other subunit units none Overlap may have. Further explanations of this simplified and in most cases preferred comparison method can be taken from the figure part.
  • the diversity of the patterns indicates a different distribution of the individual fibers in a selected area section.
  • the bundles comprising carbon fibers are typically reinforced uniformly spaced at regular intervals distributed over the entire surface of the pile layer. This circumstance also results from the fact that the bundles have an increased tendency to distribute themselves equally over the entire area during the pile forming process in the pile forming machine under mechanical stress.
  • the foreign fibers which occur at a sometimes smaller number in the pile layer, can also be randomly distributed over the surface of the pile layer, but are sometimes present in much lower concentrations.
  • these individual fibers have a different behavior when mechanically processed in a pile forming machine, so that they typically have a different distribution.
  • the foreign fibers can still be connected to individual carbon fibers or carbon fiber agglomerates, so that free movement, independently of the other carbon fibers during the flame forming process, can also be partially prevented.
  • the foreign fibers can have a completely different length distribution than the carbon fibers.
  • the pattern of the carbon fibers in the pile layer differs significantly from the patterns of the foreign substances or foreign fibers.
  • the first pattern has a higher order than the second pattern. The order is determined according to the mathematical aspects which are to be applied in connection with patterns and complex arrangements.
  • the foreign fibers have a tensile strength which is lower by at least a factor of 1.5, in particular by a factor of 2, compared to the carbon fibers.
  • the lower strength of the foreign fibers does not or only insignificantly reduces the strength of the pile layer or of the fiber composite material produced therefrom, since the carbon fibers are present in sufficient quantities. In particular for applications in the automotive industry, the very small but nevertheless possible loss of strength are insignificant.
  • the foreign fibers are sewing or knitting threads. Accordingly, sewing or knitting threads, which were originally intended to fix a reusable, ie to be recycled textile, without depositing from the carbon fibers or from the carbon fiber bundles together with the covered by this Texil carbon fibers of pile formation can be supplied. On the one hand, this reduces the production outlay and ensures the production of a relatively less expensive pile layer. Furthermore, it can also be provided that at least some of the foreign fibers have a different color than the carbon fibers.
  • optical impairments may be considered to remove the foreign fibers from the composite of the pile layer.
  • the foreign fibers are longer by about 50%, preferably even 100%, than the carbon fibers of the bundles on average.
  • hardening threads may still be contained in the pile layer, which are taken from the recycling process.
  • Hardening threads are in particular knitted threads or sewing threads with which carbon fiber textiles can be solidified, which, however, have not been removed further in the course of the recycling process.
  • these threads typically have a significantly lower brittleness than carbon fibers, these threads are not shortened so much even when processed with a mill, in particular a hammer mill, such as carbon fibers.
  • these threads are typically already present in a longer length in the textile article to be reused.
  • the foreign fibers are glass fibers and / or polyester fibers. These are preferably used in conjunction with carbon fibers auxiliary fibers, which are preferably used in particular in textile structures for the provision of a pre-consolidation.
  • polyester fibers are preferably used for sewing or forking individual textile layers.
  • Other fibers may also be: polyamide fibers, polyethylene fibers, polypropylene fibers or the like.
  • the foreign substances at least partly have a chemical binder, in particular a resin.
  • the binder is therefore not necessary to remove a binder from the fiber surface, or to remove it completely before the fibers are fed to a flame forming process. Rather, fractions of this binder can be incorporated into the pile layer, but without having to limit the requirements in terms of strength of the later to be produced fiber composite material. Rather, the binder can even contribute to a preconsolidation of the fibers in the pile layer, which is why the pile layer can have approximately an improved cohesion of the fibers. Accordingly, such a pile layer is easier to handle and can be subjected to greater mechanical stress during subsequent processing. Further, it is possible that the binder is identical to the resin with which the pile layer is subsequently treated to produce a fiber composite material. Alternatively, the binder may also be chemically compatible with another resin which serves for the subsequent production of a fiber composite material by means of the pile layer.
  • the plurality of bundles comprising carbon fibers are not longer than 15 cm, and in particular not longer than 10 cm.
  • the relative bundle content in the pile layer can be improved while maintaining the fiber content.
  • this pro-rata promotes the strength provided to the pile layer by the bundles.
  • the bundles may also be necessary for the bundles to have sections which have a suitable orientation in a predetermined direction in order to achieve a direction-specific improvement in strength.
  • this sometimes requires that the bundles do not fall short of a minimum length.
  • the bundles comprise at least 200, preferably at least 500 and more preferably at least 1000 carbon fibers.
  • the strength which the pile layer obtains from a possible orientation of the bundles can be increased, with the As a consequence, an improved direction-dependent strength is likewise imparted to the fiber composite material to be subsequently produced.
  • carbon fiber textiles from a recycling process, which typically have strands of more than 1000 fibers per strand. Through a suitable process, these are processed in a reusable carbon fiber textile such that the strands are digested to a minimum fiber number.
  • the strands or bundles can in some cases be further disrupted, but not stronger, than an execution-related number of fibers remains in the pile layer.
  • the pile layer has a basis weight (basis weight) of at most 50 g / m 2 and not less than 10 g / m 2, preferably between 35 g / m 2 and 25 g / m 2.
  • basis weight basis weight
  • Such pile layers are particularly sought after in the automotive industry in particular, since they have sufficient strength in the subsequently produced fiber composite material, but to allow the weight of the component to be reduced very greatly.
  • the surface masses of the invention enable efficient use of the valuable raw material carbon fibers while at the same time ensuring compliance with the minimum strength requirements. The ratio of required strength to the present weight is therefore particularly advantageous.
  • the object underlying the present invention is also achieved by a nonwoven or nonwoven fabric which has at least two pile layers according to one of the preceding claims, and which are in particular needled together.
  • the strength-increasing properties of the pile layer can be further improved.
  • the directional or orientation properties can be adjusted by a suitable orientation of the at least two pile layers with respect to each other.
  • the one pile layer it is possible for the one pile layer to be arranged with a first orientation, but the second pile layer is arranged with respect to a further second orientation, which differs from the first orientation.
  • This allows to define a plurality of preferred directions within a nonwoven fabric or a nonwoven fabric layer. In this case, for example, the bundles already have a preorientation and thus also give the pile layer a suitable orientation. Breaking the bundles into individual fibers by needling is to be excluded in the context of the present invention.
  • the nonwoven fabric it can also be provided that it has a pile layer according to the previously described embodiments, which is needled for solidification. Needling causes a further entanglement of the fibers covered by the pile layer, in particular an entanglement, which takes place locally and thus brings about a local solidification. If the pile layer is needled by a sufficient number of sufficiently dense needle stitches, the entire structure of the pile layer can be given a significantly improved strength.
  • the orientation of the curved bundles in a pile layer differs from one another by at least 5 ° relative to the orientation of the curved bundles in another pile layer, in particular by an angle of 15 °, 30 °, 45 °, 60 °, 75 ° or 90 °.
  • This makes it possible, in particular in a simple manner, to form preferred preferred directions within the nonwoven or the nonwoven fabric with a defined angular deviation. This is in the context of processing in automotive vehicle construction of great advantage, since the preferred directions can be adjusted in a suitable manner relative to the applications.
  • At least two pile layers are needled together or a pile layer for solidification, wherein on average at least one needling stitch, preferably at least five needling stitches are present on an area of 1 cm 2 .
  • the designated area refers to the needle-punched area of the pile layer or layers, which preferably represents the entire area of the pile layer or layers.
  • the number of localized consolidations is sufficiently large to effect solidification extending over the entire selected area of the pile layer (s). This is particularly possible if, with a uniform subdivision of the pile layer or the pile layers into subunits of 1 cm 2 , each subunit has the number of needling stitches according to the design.
  • the needling stitches provide a sufficient number of openings in the pile layer (s) to serve as flow channels for more efficient impregnation with a liquid resin or liquid polymer. Namely, the openings allow efficient transfer of the resin or polymer over the entire needling thickness and thus over the entire thickness of the pile layer (s). This reduces on the one hand the impregnation time and thus also the production time of components of which the pile layer (s) are enclosed.
  • a resin-impregnated component has a previously described pile layer or a previously described fleece or a previously described nonwoven, which component is formed in particular as a component of a vehicle.
  • Such components may comprise the described pile layers, nonwovens or nonwovens alone or in combination with other textile structures.
  • the described pile layers, nonwovens or nonwoven fabrics may be comprised in connection with a scrim and / or a fabric of the component, wherein the scrim and / or fabric is provided primarily for load-bearing.
  • the components of a vehicle, which have the described pile layers, nonwovens or nonwovens are not provided to ensure the passive safety of a vehicle.
  • these components are preferably designed as parts of the outer shell of a vehicle.
  • the component may be resin-impregnated, wherein a complete impregnation or even a partial impregnation can be achieved.
  • the resin-impregnated component can be cured. Under the execution resin impregnation is also expected a suitable polymer impregnation.
  • the method does not include a step of separating the foreign substances or a step of partially separating foreign substances.
  • the impurities are thus introduced into the pile layer and increase their basis weight, the impurities, in particular the foreign fibers, are not or only marginally responsible for the strength in the fiber composite material to be produced later, so that the carbon fibers, which are also present, have a sufficient and can ensure desired strength. It can also be provided that bundles comprising carbon fibers obtained in a recycling process can be used for producing a pile layer, in particular for producing a pile layer described above, by carrying out a method described as being according to the invention or as described in the description.
  • 1 a shows a first embodiment of a pile layer according to the invention in a plan view
  • FIG. 1b shows the carbon fiber content of the pile layer according to FIG. 1a in isolated view
  • FIG. 1c shows the foreign fiber content of the pile layer according to FIG. 1a in isolated view
  • FIG. Fig. 2 is a schematic representation of the foreign fiber content accordingly
  • FIG. 1 c in conjunction with a planar division to characterize the pattern or the order of the pattern of the foreign fibers
  • Nonwoven fabric in supervision; 4 shows a flowchart for illustrating the sequence of individual steps, which are encompassed by an embodiment of the method according to the invention. It should be noted for the sake of completeness that the embodiments shown are merely schematic representations. In particular, sizes and proportions may differ from those of the representations shown in a specific item.
  • 1 shows a first embodiment of a pile layer 1 according to the invention with a plurality of bundles 2 comprising carbon fibers 10. In the present case, the bundles have a preferred curved course, but may also have any other technically possible course. The curvature of the present bundles results from processing with a carding device.
  • the bundles 2 are intertwined with other fibers comprised of the pile layer 1, which may also be carbon fibers 10, and thus make it possible to provide a pile layer 1 with sufficient strength to be removed, for example, from a pile forming machine as an entire structure to be able to.
  • the pile layer 1 according to Figure 1 a also includes a number of foreign substances 20, in particular in the form of foreign fibers 20, which are shown in bold. These foreign substances 20, or foreign fibers 20 are shown in an isolated representation again in Fig. 1 c.
  • the foreign substances 20, and the foreign fibers 20 in each case random arrangement.
  • the course of the foreign substance 20, or the foreign fiber profile shows no regularity.
  • the individual foreign substances 20, or foreign fibers 20 in relation to each other purely randomly arranged.
  • the bundles have a relatively similar curved course. This is characterized by a vertex area which has the largest curvature in the course of a bundle. The apex region is arranged between the bundle ends, the bundle end regions having only a relatively smaller curvature compared to the crest region. Sometimes the Bundendend Suitee are not curved at all.
  • the bundles 2 not only have a preferred direction, for example in the direction of the fiber path at the bundle end regions, but also approximately in a direction tangential to the vertex region.
  • the curved course thus ensures that the bundles 2 not only have a preferred direction with respect to the force absorption, but also another deviating therefrom, in particular perpendicular to the first preferred direction extending preferred direction.
  • the curvature of a bundle 2 is determined in the context of the present invention from the average directional course of all the fibers in the bundle 2.
  • the fibers of a bundle are detected for this determination in terms of their individual spatial position, wherein the average layer is calculated from comparable sections of individual fibers in the bundle 2.
  • the mean profile is substantially coincident with that of the fiber which is in the center of the bundle 2 is arranged relative to the cross section.
  • the mean profile of the bundle 2 will only have to be determined by averaging the layers of all comparable sections of the individual fibers.
  • the mean value formation for determining the average course is possible for the person skilled in the art by means of common considerations.
  • the bundles 2 have a comparable orientation.
  • the distances of the individual bundles 2 from the bundles 2 adjacent to each other are not substantially different for all bundles 2.
  • This relates to the spacings of the respective adjacent bundles 2 both laterally in accordance with the illustration in FIG. 1 b and the distances to the next bundle 2 above or below a bundle 2 in the respective representation.
  • a pattern can be taken from the arrangement of the individual bundles 2 in Figure 1 b, which can not be determined in the arrangement of foreign substances according to Fig. 1 c.
  • the considered surface section of the pile layer 1 for example a surface section of 20 cm by 20 cm, can be divided into equal bottom surface sections in the simplest way. This is indicated schematically in FIG.
  • the surface section shown was divided into a checkerboard-like pattern of 32 by 32 lower surface sections.
  • the respective lower surface sections can now be assigned a value depending on the density of impurities or on the density of foreign fibers in a respective lower surface section.
  • the foreign substance density as well as the foreign fiber density is to be normalized to the total density or total fiber density.
  • a value of 1 could be assigned if impurity fractions are present in a sub-surface section, and 0 if no impurity fractions or foreign-fiber fractions are present in the underfloor section. cut are present.
  • this simple subdivision is only meaningful if there is a sufficient number of subunit units that have no impurity components or foreign fiber components in the distribution. Otherwise, a finer subdivision is appropriate in most cases.
  • Such a subdivision could, for example, as already explained above, consist in applying a scale of -5 to +5 and assigning an integer value depending on the impurity density or depending on the foreign fiber density, the lowest density being to be evaluated with -5 and the highest density +5. If now a comparable approach is also applied to the carbon fiber distribution, as shown in FIG.
  • the individual comparable subunit units would in most cases be assigned a different value than in the case of the foreign substance density or foreign fiber distribution.
  • the individual values of the sub-surface units corresponding to one another can be compared with one another. Mathematically, this comparison could be carried out, for example, by subtracting the values of the respectively comparable sub-surface units from one another.
  • both patterns were identical, the subtraction would yield a value of zero for each subunit unit.
  • the more different the patterns are the more different are the individual values which give the subtractions of the sub-surface units. Accordingly, a measure of the difference in the patterns to be compared is obtained. From a practical point of view, it could be determined that the two patterns differ when the subtraction of the values of all comparable subunit units exceeds an average limit value. For example, the patterns could differ if the sum over all subtraction values of all subunit units normalized to the total number of subunit units exceeds a predetermined value. According to the preselected scale division, this value must be sensibly determined. For example, on a scale from -5 to +5, it could be 0, 1.
  • the determination of the differences in the patterns of the two considered surface sections is relatively simple, since the distribution of the carbon fibers 10 differs significantly from the distribution of the foreign matter 20 or foreign fibers 20.
  • the difference is in any case already perceptible with the eye. This is the case in particular, since the distribution of the foreign substances 20 or of the foreign fibers 20 does not even cover numerous sub-surface units of the considered surface section. However, if there is an overlap of most or even all sub-surface units, a simple comparison of the patterns by subtracting the values of the respective comparable sub-surface portions can sometimes give a false image.
  • certain patterns may not immediately be obvious, since the patterns are barely perceptible in the amount of carbon fibers 10 or foreign substances 20 present.
  • the area autocorrelation for all subunit units can be calculated, which is sometimes better able to take into account existing regularities in the patterns in the calculation.
  • Nonwoven fabric which has been produced from two layers of a pile layer 1 by doubling. If a nonwoven fabric is present, it may have been consolidated by needling the two layers of the pile layers 2.
  • the two pile layers 2 are arranged relative to one another in such a way that their respective preferred directions are arranged rotated by a certain angle relative to each other. In this way, the strength-increasing properties, which can be derived from the preferred directions of the individual pile layers 2, can be adapted to each other in a direction-specific manner.
  • a relative arrangement of the two pile layers 1 to each other may preferably by an angular amount of 15 °, 30 °, 45 °, 60 °, 75 ° and 90 ° rotated. In the present case, the relative arrangement of the two pile layers 1 is arranged rotated by approximately 45 ° with respect to one another.
  • FIG. 4 relates to a flow chart for illustrating the sequence of individual steps which are encompassed by an embodiment of the method according to the invention for producing a pile layer. Accordingly, it is necessary to cut a flat structure comprising carbon fibers 10 comprising bundles 2 and at least partially fixed by foreign substances 20, in particular by knitting threads. Cutting can be understood here in its most general form and includes, for example, a step of punching. Further, it is necessary that the cut sheet is processed for partially breaking up the bundles 2 into individual fibers, in particular in a hammer mill; Furthermore, a step of introducing the batch partially digested by this processing into a pile forming machine, in particular into a carding machine, is included.
  • the Florsche- machine is then operated in such a way that the bundles 2 are not completely singulated into individual fibers, but carbon fibers 10 of the bundles 2 are engulfed with other fibers. Subsequently, the pile layer thus produced is removed from the pile forming machine.
  • the method does not include a step of depositing the foreign substances 20 or foreign fibers 20.
  • the pile layers can then also be processed into nonwovens or nonwovens.
  • needling or stitching or thinning may be considered.
  • the curved bundles 2 extending from the pile layers 1 should not or only partially be damaged.

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  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Inorganic Chemistry (AREA)
  • Nonwoven Fabrics (AREA)
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Abstract

L'invention concerne une couche de voile qui présente une pluralité de faisceaux partiellement décomposés sous forme de fibres individuelles et contenant des fibres de carbone, ainsi que des corps étrangers, les fibres de carbone représentant au moins 70% en masse de la masse totale de la couche de voile et les corps étrangers ne représentant pas plus de 30%, mais pas moins de 2%, les corps étrangers provenant d'un processus de recyclage.
EP11782098.5A 2010-11-03 2011-11-03 Couche de voile présentant des faisceaux contenant des fibres de carbone Withdrawn EP2635733A1 (fr)

Applications Claiming Priority (11)

Application Number Priority Date Filing Date Title
DE102010043346 2010-11-03
DE102010043345 2010-11-03
DE102010043347 2010-11-03
DE102010043349 2010-11-03
DE102010043300 2010-11-03
DE102011077880 2011-06-21
DE102011077879 2011-06-21
DE102011077881 2011-06-21
DE102011078741 2011-07-06
DE102011078739 2011-07-06
PCT/EP2011/069316 WO2012059540A1 (fr) 2010-11-03 2011-11-03 Couche de voile présentant des faisceaux contenant des fibres de carbone

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EP11782096.9A Active EP2635732B1 (fr) 2010-11-03 2011-11-03 Tissu non tissé renforcé
EP11782097.7A Active EP2635417B1 (fr) 2010-11-03 2011-11-03 Couche de tissu à poils ayant des faisceaux de fibres courbés

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CN (3) CN103025494A (fr)
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ES2544991T3 (es) 2015-09-07
MX336749B (es) 2016-01-29
CA2802301C (fr) 2016-04-26
CA2802296C (fr) 2015-03-24
MX2012014598A (es) 2013-02-07
EP2635417B1 (fr) 2015-09-02
EP2635732A1 (fr) 2013-09-11
CN103025494A (zh) 2013-04-03
US9551098B2 (en) 2017-01-24
PT2635417E (pt) 2015-12-22
BR112012031770A2 (pt) 2017-02-21
PL2635732T3 (pl) 2015-10-30
JP2013535588A (ja) 2013-09-12
BR112012031770A8 (pt) 2018-01-02
PL2635417T3 (pl) 2016-04-29
KR101494507B1 (ko) 2015-02-17
CN103025942A (zh) 2013-04-03
JP2013540902A (ja) 2013-11-07
KR20130042504A (ko) 2013-04-26
WO2012059538A1 (fr) 2012-05-10
JP5728577B2 (ja) 2015-06-03
MX2012014612A (es) 2013-02-07
US20130209724A1 (en) 2013-08-15
KR20130042506A (ko) 2013-04-26
CA2802315C (fr) 2015-01-06
CA2802296A1 (fr) 2012-05-10
US20130209725A1 (en) 2013-08-15
KR20130054968A (ko) 2013-05-27
JP5745052B2 (ja) 2015-07-08
JP5718462B2 (ja) 2015-05-13
CN103025942B (zh) 2016-10-05
WO2012059539A1 (fr) 2012-05-10
CA2802301A1 (fr) 2012-05-10
KR101497788B1 (ko) 2015-03-02
EP2635417A1 (fr) 2013-09-11
JP2013534278A (ja) 2013-09-02
US20130287991A1 (en) 2013-10-31
CA2802315A1 (fr) 2012-05-10
HK1181433A1 (zh) 2013-11-08
WO2012059540A1 (fr) 2012-05-10
CN103025940B (zh) 2016-03-09
MX2012014614A (es) 2013-02-07
CN103025940A (zh) 2013-04-03
KR101577861B1 (ko) 2015-12-15
EP2635732B1 (fr) 2015-05-13
ES2554928T3 (es) 2015-12-28

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