EP3553213A2 - Verbesserungen an oder im zusammenhang mit polymermaterialien - Google Patents

Verbesserungen an oder im zusammenhang mit polymermaterialien Download PDF

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Publication number
EP3553213A2
EP3553213A2 EP19166625.4A EP19166625A EP3553213A2 EP 3553213 A2 EP3553213 A2 EP 3553213A2 EP 19166625 A EP19166625 A EP 19166625A EP 3553213 A2 EP3553213 A2 EP 3553213A2
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EP
European Patent Office
Prior art keywords
elongate
elongate element
fabric
polymeric material
composite
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.)
Pending
Application number
EP19166625.4A
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English (en)
French (fr)
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EP3553213A3 (de
Inventor
John Patrick HYND
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.)
Don and Low Ltd
Original Assignee
Don and Low Ltd
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 Don and Low Ltd filed Critical Don and Low Ltd
Publication of EP3553213A2 publication Critical patent/EP3553213A2/de
Publication of EP3553213A3 publication Critical patent/EP3553213A3/de
Pending legal-status Critical Current

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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D02G3/045—Blended or other yarns or threads containing components made from different materials all components being made from artificial or synthetic material
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
    • D02G3/402—Yarns in which fibres are united by adhesives; Impregnated yarns or threads the adhesive being one component of the yarn, i.e. thermoplastic yarn
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/06—Threads formed from strip material other than paper
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Definitions

  • This invention relates to a tape or yarn, such as a polymeric/thermoplastic/polyolefin tape or yarn, to a fabric or material formed from said tape or yarn, to an article, item or product made from said fabric or material, such as a thermoformed article, and to a method of making or forming same.
  • a tape or yarn such as a polymeric/thermoplastic/polyolefin tape or yarn
  • the invention particularly, though not exclusively, relates to a thermoplastic tape or yarn, to a thermoplastic material or fabric and a method of producing same.
  • the material or fabric e.g. composite material or fabric
  • composite materials or fabrics of the present invention may be comprised in articles used for high impact, anti-ballistic and/or defensive purposes.
  • Composite materials or fabrics of the present invention may be comprised in articles to afford high-impact resistance properties.
  • Embodiments of the present invention relate to composite elongate elements, such as tapes or yarns, which may be used to produce a fabric or material incorporating similar or dissimilar materials in the warp and weft, such fabric being suitable for consolidating into single layer or multilayer shells or structures, e.g. under the action of heat and pressure without the need for additional resin or adhesive.
  • srPP Self-reinforcing polypropylene
  • WO 91/11324 discloses a thermoplastic composite material or tape comprising a molecularly-oriented thermoplastic polymer base having at least one thermoplastic surface polymeric layer compatibly bonded to said polymer base by molecular interspersion between the contiguous surfaces of the adjoining base and surface layers, and said surface polymeric layer having a softening temperature lower than that of the polymer base.
  • GB 2 492 644 discloses a fabric or material comprising: at least first elongate elements and second elongate elements that are mutually interspersed; wherein the first elongate elements comprise a polymer base and at least one polymeric surface layer, wherein the at least one polymeric surface layer has a softening temperature lower than that of the polymer base; and wherein at least a surface of the second elongate elements comprises an ultra high molecular weight polyalkylene (UHMWPA), wherein the ultra high molecular weight polyalkylene is a material dissimilar to the polymeric surface layer, and the first elongate elements are fusible together with the second elongate elements at least at intersections.
  • UHMWPA ultra high molecular weight polyalkylene
  • molecular interspersion is meant the intimate molecular compatibility of molecules of the surface layer and the adjacent polymer and vice versa, so that there is intermingling or fusion at their contiguous boundaries. It is believed that such molecular interspersion effectively forms an amorphous sheath which protects the polymer base against fracture during drawing, thus providing mutual mechanical reinforcement.
  • Mutual mechanical reinforcement involves the surface material being capable of high elongation when drawn in the solid state (or even being drawn at a temperature above its softening point, i.e. in the molten state). With a polymer layer of high modulus, and crystalline or oriented material sandwiched between amorphous high elongation surface layers, propagation of transverse fractures is inhibited allowing the total composite to be highly drawn.
  • Coextruded yarns of thermoplastic polymers of at least A-B construction, where A has a melting temperature at least 10°C below that of B can be formed into fabrics eg. woven fabrics, which can, in turn, be formed into three dimensional shaped articles under the influence of heat and pressure without the need for additional adhesives or films.
  • these yarns can be limited in their ratio of A to (A+B) to between 1 to 30% or less, more typically 1 to 15% or less. This can limit the strength of bonding of the tape or yarn both internally to itself and also externally to other materials.
  • a fabric can be made from said tapes or yarns, e.g. by weaving, which is capable of being formed into 2 or 3 dimensional items under the action of heat and pressure both by itself and in conjunction with dissimilar materials. The bond strength of such fabric can be limited.
  • the fabric or material may, therefore, be self-adhering or self-supporting.
  • an elongate element or braid such as a composite and/or twisted elongate element or braid, comprising a plurality of elongate elements twisted or braided together and which comprise at least one first elongate element and at least one second elongate element, wherein the or each first elongate element comprises or consists of a first polymeric material A and the or each second elongate element comprises or consists of a second polymeric material B.
  • 'composite elongate element or braid' is meant to comprise or include a plurality of elongate elements, yarns, tapes, strands, plies, or fibres that are twisted or braided together.
  • twisting or braiding together of the plurality of elongate elements may provide advantage over the prior art, e.g. weaving together of single yarns.
  • An advantage may be beneficial increased distribution of the first polymeric material throughout a matrix of a material or fabric, e.g. a woven material.
  • the first polymeric material may comprise a first polyolefin.
  • the second polymeric material may comprise a second polyolefin.
  • the first polymeric material may act as a matrix binder or adhesive agent within the material or fabric.
  • the second polymeric material may act as a strengthening or integrity providing agent within the material or fabric.
  • Each of the plurality of elongate elements and/or the composite elongate elements may have tensile strength, but may be too flexible to provide compressive strength.
  • The/each of the plurality of elongate elements and/or composite elongate elements may be coilable or reelable.
  • the composite elongate element(s) may be capable of being woven.
  • the elongate elements may be twisted or 'laid' together.
  • first polymeric/polyolefinic material and the second polymeric/polyolefinic material may be dissimilar, e.g. beneficially dissimilar polymers/polyolefins.
  • a melting point or softening point MP A of the first polymeric material is lower than a melting point or softening point MP B of the second polymeric material.
  • the first and second polymeric materials may be thermally compatible and/or capable of being autogenously bonded.
  • the melting point or softening point MP A of the first polymeric material may be at least 10°C less than the melting point or softening point MP B of the second polymeric material.
  • the first elongate element(s) may (substantially) solely consist of the first polymeric material, e.g. a first homopolymer.
  • the second elongate element(s) may (substantially) solely consist of the second polymeric material, e.g. a second homopolymer.
  • the first elongate element(s) may comprise a single and/or homogeneous layer.
  • the second elongate element(s) may comprise a single and/or homogeneous layer.
  • the second polymeric material may comprise or substantially comprise polypropylene, e.g. polypropylene homopolymer.
  • the first polymeric material may comprise or substantially comprise polyethylene, e.g. polyethylene homopolymer.
  • the elongate element or braid may comprise one or more first elongate elements twisted (together) with one or more second elongate elements.
  • the elongate element or braid may comprise a first elongate member twisted (together) with a second elongate member.
  • the elongate element or braid may comprise one first elongate member twisted (together) with two second elongate members.
  • the elongate element or braid may comprise one first elongate member twisted (together) with three second elongate members.
  • the elongate element or braid may comprise one or more first elongate elements twisted (together) with one or more second elongate elements so as to form a composite and/or twisted elongate element or braid, and two or more of said composite and/or twisted elongate elements twisted (together).
  • first twist between the first and second elongate elements.
  • second twist between the two or more composite and/or twisted elongate elements.
  • the first and second elongate members may have a similar or substantially the same tex (mass in grams per 1,000 metres), e.g. 70 to 200 grams/1,000 metres, or 100 to 130 grams/1,000 metres).
  • the plurality of elongate elements may comprise two elongate elements. In another embodiment of the present invention the plurality of elongate elements may comprise three elongate elements. Alternatively, the plurality of elongate elements may comprise more than three elongate elements.
  • the plurality of elongate elements may be twisted together in a left-handed or S-twist or in a right-handed or Z-twist (according to ISO 2).
  • the at least one elongate element may be substantially planar, e.g. comprises a tape, prior to twisting or braiding.
  • each of the plurality of (e.g. first and/or second) elongate elements may be substantially planar, e.g. comprise tapes, prior to twisting or braiding.
  • surfaces of adjacent elongate elements may contact or touch one another.
  • At least one/each of the plurality of elongate elements may be an extruded yarn or tape, for example, made by an extrusion process.
  • the at least one second elongate element or yarn may comprise a self-reinforcing polymeric material such as self-reinforcing polypropylene (srPP).
  • the at least one (second) elongate element may comprise a thermoplastic(s).
  • The/each at least one second elongate element may comprise a molecularly-oriented (thermoplastic) polymeric material.
  • Polymeric molecular orientation may be or substantially be along a longitudinal direction of the/each at least one (second) elongate element.
  • The/each at least one second elongate element may be selected from polypropylene, polyesters, polyethyleneterephthalate, polyamides, Nylon (e.g. Nylon 6 or 6.6), or a polyethylene, e.g. having a density in the range 0.940 to 0.970, or linear low density polyethylene.
  • the second polymeric material may comprise a molecularly-oriented polyolefin polymer, such as a polypropylene polymer.
  • the first polymeric material may comprise a thermoplastic polymer or polyolefin or co-polymer.
  • the first polymeric material may comprise ethylene-propylene co-polymer, polybutylene, polybutene-1 or a co-polymer comprising two or more of butylene, ethylene and propylene, co-polyesters and co-polyamides.
  • the second polymeric material may comprise polypropylene and/or the first polymeric material may comprise an ethylene-propylene co-polymer, a polybutylene such as polybutene-1 or a co-polymer comprising two or more of butylene, ethylene and propylene.
  • the second polymeric material may comprise polyester and/or the first polymeric material may comprise a co-polyester, or the second polymeric material may be a polyamide and the first polymeric material may comprise a co-polyamide.
  • the first polymeric material may be thermally compatible/bondable/bonded and/or autogenously bondable/bonded with the second polymeric material.
  • the second polymeric material may have a softening point of 10°C or more higher than the softening point of the first polymeric material.
  • a material or fabric such as a thermoplastic composite material, comprising at least one elongate element, such as at least one composite elongate element or braid according to the first aspect of the present invention.
  • the material or fabric may comprise a plurality of (composite) elongate elements according to the first aspect of the present invention.
  • the material or fabric may advantageously comprise a single layer of material or fabric.
  • the material or fabric e.g. advantageously single layer of material or fabric, may be consolidated or consolidatable, e.g. by application of heat and/or pressure.
  • the material or fabric of the present invention has been found to possibly provide advantages over the prior art, e.g. it has been found that since a single layer of the material or fabric may be heavier than a single layer of single yarn weave of the prior art, whereas in the prior art single layers have been laminated together to provide a suitable material for forming of a product, a single layer of fabric of the present invention suffices. This may avoid the need for lamination, so simplifying the manufacturing process and/or obviating and/or mitigating the problem of delamination.
  • the material or fabric may also comprise a plurality of further elongate elements, e.g. twisted elongate elements, which may be polymeric.
  • the plurality of further elongate elements may beneficially be the same as the plurality of composite elongate elements.
  • the plurality of composite elongate elements and plurality of further elongate elements may be mutually interspersed.
  • At least some of the further elongate elements may comprise a material or materials similar or dissimilar to the first polymeric material.
  • Adjacent, e.g. side-by-side, overlaid, cross-laid or intersecting, elongate elements may be fusible together at least at intersections.
  • Fusing may comprise heating the fabric above the melting temperature of the first polymeric material A, e.g. at a temperature between MP A and MP B .
  • Fusing may comprise cooling the fabric to allow the surface layer to solidify.
  • Fusing the elements may comprise subjecting the fabric to pressure. Fusing may be achieved by single closure press with flat or contoured plates, continuous belt press, induction heated press or via vacuum bagging and autoclaving.
  • the material or fabric may comprise a woven material or fabric.
  • the material or fabric may comprise at least one mat of mutually intersecting elongate elements fusible together at least at their intersections.
  • thermoplastic material or fabric may comprise a consolidated mat or sheet, wherein the plurality of (composite) elongate elements may have been consolidated together, e.g. by application of heat and/or pressure.
  • the fabric or material may be formed without the use of, for example, a resin matrix material, a film or an adhesive.
  • the elongate elements and/or further elongate elements may be selected from tapes, threads, fibres, filaments, strands, or the like.
  • the further elongate elements may comprise a single layer and/or homogenous layer.
  • the further elongate elements may comprise a material or material similar or dissimilar to the first polymeric material.
  • the elongate elements or members and the further elongate members may be formed as tapes.
  • the elongate elements and/or further elongate elements may be woven, knitted, stitched, or may be laid out to form a random fibrous web or may be randomly interspersed to form the material.
  • the elongate elements and/or further elongate elements may be woven together to form a fabric.
  • the composite elongate elements and further elongate elements may be woven together to form the fabric or material.
  • the warp may be formed of composite or further elongate elements and the weft may be formed of the other.
  • the warp may be formed of composite elongate elements and the weft may be formed of further elongate elements.
  • the warp may be formed of further elongate elements and the weft may be formed of composite elongate elements.
  • the composite and further elongate elements may be woven together to form the fabric or material, and the warp and/or the weft may comprise a mixture of composite and further elongate elements.
  • the mixture of composite and further elongate elements may be a random arrangement of composite and further elongate elements.
  • the mixture of composite and further elongate elements may be a regular alternation of composite and elongate elements.
  • warp and weft may comprise, e.g. solely comprise, the composite elongate elements.
  • the further elongate elements may comprise one or more of: polyesters, polyamides, aramids, thermoplastic polymers, molecularly-oriented thermoplastic polymers, ultra high molecular weight polyalkylenes (UHMWPA), such as ultra high molecular weight polyethylene (UHMWPE) or ultra high molecular weight polypropylene (UHMWPP), multifilament nucleated polypropylenes, and/or carbon fibres.
  • UHMWPA ultra high molecular weight polyalkylenes
  • UHMWPE ultra high molecular weight polyethylene
  • UHMWPP ultra high molecular weight polypropylene
  • multifilament nucleated polypropylenes and/or carbon fibres.
  • the further elongate elements may be formed of hybrid yarns.
  • the hybrid yarns may be formed of at least two different materials or fibres comprising polyesters, polyamides, aramids, thermoplastic polymers, molecularly-oriented thermoplastic polymers, ultra high molecular weight polyalkylenes (UHMWPA), such as ultra high molecular weight polyethylene (UHMWPE) or ultra high molecular weight polypropylene (UHMWPP), multifilament nucleated polypropylenes, and/or carbon fibres.
  • UHMWPA ultra high molecular weight polyalkylenes
  • UHMWPE ultra high molecular weight polyethylene
  • UHMWPP ultra high molecular weight polypropylene
  • multifilament nucleated polypropylenes and/or carbon fibres.
  • the further elongate elements may be formed of hybrid yarns selected from hybrid yarns comprising aramids and UHMWPE or hybrid yarns comprising polypropylene.
  • the further elongate elements may comprise or consist of ultra high molecular weight polyalkylenes selected from UHMWPE or UHMWPP.
  • a laminated material such as a rigid and/or self-supporting laminated material, comprising a plurality of layers, wherein at least one of said layers comprises a material or fabric according to the second aspect of the present invention.
  • the laminated material comprises two layers, e.g. only two layers, or three layers, e.g. only three layers.
  • each layer comprises a material or fabric according to the second aspect of the present invention.
  • an article such as a formed and/or three-dimensional and/or rigid and/or self-supporting article, beneficially formed from a (single layer of) material or fabric of the second aspect of the present invention, or alternatively formed from a laminated material of the third aspect of the present invention.
  • the article may be formed by a moulding technique, e.g. press-moulding.
  • the article may be capable of withstanding relatively high impact, i.e. the article may have high impact resistance properties.
  • the article may comprise a luggage shell, e.g. a shell for a suitcase, or at least part of a container.
  • the article may comprise or be selected from: an armour product, e.g. body armour, an automotive (vehicle) component, a sportswear product.
  • the article may be adapted for antiballistic purposes and/or comprises bulletproof vests, body armour, panels suitable for the protection of vehicles, such as military and/or commercial vehicles, bin liners, blast basket or blast blankets to contain fragmentation debris from the detonation of explosive devices.
  • the article may find use as carpet backing which may be used in automotive or aerospace application, or which may comprise panels suitable for use on automotive vehicles.
  • the article may comprise a toe-cap(s) for protective footwear, connecting straps of handles of intermediate bulk containers or the containers themselves, tarpaulins, packaging, luggage, protective cases, pipes.
  • a method of forming a composite elongate element or braid comprising:
  • thermoplastic (composite) material a method of forming a fabric or material, such as a thermoplastic (composite) material, the method comprising:
  • Said fabric or material may comprise a sheet or mat.
  • Said step of providing may also comprise providing a plurality of further elongate elements, which may be polymeric.
  • Said step of forming may comprise weaving.
  • the plurality of (composite) elongate elements may comprise warp yarns.
  • the plurality of (composite) elongate elements may comprise weft yarns.
  • the method may further comprise the (subsequent) step of consolidating the fabric or material, e.g. single layer fabric or material, by application of heat and/or pressure.
  • a seventh aspect of the present invention there is provided a method of forming an article, such as a three-dimensional and/or rigid and/or self-supporting article, comprising the steps of:
  • 'composite elongate element or braid' is meant to comprise or include a plurality of elongate elements, yarns, tapes, strands, plies, or fibres that are twisted or braided together.
  • twisting or braiding together of the plurality of elongate elements provides advantage over the prior art, e.g. weaving together of single yarns.
  • An advantage is believed to be beneficial increased distribution of the first polymeric material throughout a matrix of a material or fabric, e.g. a woven material.
  • the first polymeric material A comprises a first polyolefin.
  • the second polymeric material B comprises a second polyolefin.
  • the first polymeric material A acts as a matrix binder or adhesive agent within the material or fabric.
  • the second polymeric material B acts as a strengthening or integrity providing agent within the material or fabric.
  • Each of the plurality of elongate elements 10 and/or the composite elongate elements 5; 5a to 5d have tensile strength, but are too flexible to provide compressive strength.
  • The/each of the plurality of elongate elements 10 and/or composite elongate elements 5; 5a to 5d are coilable or reelable.
  • the composite elongate element(s) 5; 5a to 5d are capable of being woven.
  • the elongate elements 10; 5; 5a to 5d are twisted or 'laid' together.
  • the first polymeric/polyolefinic material and the second polymeric/polyolefinic material are dissimilar, i.e. dissimilar polymers/polyolefins.
  • a melting point or softening point MP A of the first polymeric material is lower than a melting point or softening point MP B of the second polymeric material.
  • the first and second polymeric materials are thermally compatible, and/or capable of being autogenously bonded.
  • the melting point MP A of the first polymeric material is typically at least 10°C less than the melting point MP B of the second polymeric material.
  • the first elongate element(s) 20 (substantially) solely consist of the first polymeric material A, e.g. a first homopolymer.
  • the second elongate element(s) 25 (substantially) solely consist of the second polymeric material B, e.g. a second homopolymer.
  • the first elongate element(s) 20 comprise a single and/or homogeneous layer.
  • the second elongate element(s) 25 comprise a single and/or homogeneous layer.
  • the second polymeric material comprises or substantially comprises polypropylene, e.g. polypropylene homopolymer.
  • the second polymeric material comprises or substantially comprises polyethylene, e.g. polyethylene homopolymer.
  • the elongate element or braid 5; 5a to 5d comprises one or more first elongate elements 20 twisted (together) with one or more second elongate elements 25.
  • the second elongate element is: extruded, made from polypropylene, highly drawn, has molecularly aligned polymer chains, and/or has a melting point (MP B ) of 165°C or higher.
  • the second elongate element is: extruded and/or made from polyethylene.
  • the first elongate element need not be highly drawn to achieve molecular alignment. This is because the first elongate element melts away, in use, to form a matrix material, and if there is not molecular alignment, material shrinkage can be avoided.
  • the first elongate element is sacrificially melted in the elongate element/braid or twisted tape or fabric or article made therefrom.
  • the polyethylene has a melting point MP A of around 134°C.
  • the elongate element or braid 5a comprises a first elongate member 20 twisted (together) with a second elongate member 25.
  • first elongate member 20 can be twisted together with a second elongate member 25, e.g. of the same or similar tex (mass in grams of 1,000 metres).
  • the twist level is typically between 20 and 60 turns per metre, preferably around 40 tpm.
  • the resultant twisted yarn can be used to construct a fabric, e.g. a woven fabric.
  • Said woven fabric made from said tapes can then be formed into a three dimensionally formed article by the action of heat and pressure in a mould, said article then being cooled in the mould prior to release.
  • forming can be of a single layer of fabric or of multiple layers of fabric.
  • the resultant article can then display superior lamination strength versus a similar fabric formed only from conventionally coextruded A-B or A-B-A tapes or yarns with a lower ratio of A to (A+B), e.g. 15% versus 50% for the present invention.
  • the elongate element or braid 5b comprises one first elongate member 20 twisted (together) with two second elongate members 25.
  • two tapes or yarns of type B are twisted with a single tape or yarn of type A of similar tex to yield a twisted tape equivalent to 33.33% cap layer (ratio of A to (A+B)).
  • the elongate element or braid 5c comprises one first elongate member 20 twisted (together) with three second elongate members 25.
  • three tapes or yarns of type B are twisted with a ratio single tape or yarn of type A of very similar tex to yield a twisted tape equivalent to 25% cap layer (ratio of A to (A+B)), which is around twice that which can be achieved with conventionally coextruded A-B or A-B-A tapes or yarns.
  • the elongate element or braid 5d comprises one or more first elongate elements A twisted (together) with one or more second elongate elements B so as to form a composite and/or twisted elongate element or braid 5a, and two or more of said composite and/or twisted elongate elements twisted (together).
  • a second twist between the two or more composite and/or twisted elongate elements 5a In said fourth embodiment one tape or yarn of type A is twisted with one tape or yarn of type B.
  • the first and second elongate members 20, 25 advantageously have a similar or substantially the same tex (mass in grams per 1,000 metres), e.g. 70 to 200 grams/1,000 metres, or 100 to 130 grams/1,000 metres).
  • 20 to 100 e.g. 20 to 60, e.g. 40 to 60, twists/turns per metre (tpm), and preferably around 40 tpm, along a length of the (composite) elongate element 5a - 5d and/or each of the plurality of elongate elements 15, 20.
  • the plurality of elongate elements comprise two elongate elements, and n the second embodiment of the present invention the plurality of elongate elements comprise three elongate elements, in an alternative embodiment the plurality of elongate elements 10 can comprise more than three elongate elements 20, 25.
  • the plurality of elongate elements 20, 25; 5a to 5d can be twisted together in a left-handed or S-twist or in a right-handed or Z-twist (according to ISO 2).
  • at least one/each of the plurality of elongate elements is/are substantially planar, e.g. comprises a tape, prior to twisting or braiding.
  • surfaces of adjacent elongate elements 20, 25 contact or touch one another.
  • The/each elongate element 20, 25 is an extruded yarn or tape, for example, made by an extrusion process.
  • the at least one second elongate element or yarn 25 comprises a self-reinforcing polymeric material such as self-reinforcing polypropylene (srPP).
  • The/each elongate element 20, 25 comprises a thermoplastic(s).
  • The/each at least one second elongate element 25 comprises a molecularly-oriented (thermoplastic) polymeric material.
  • The/each at least one second elongate element 25 can be selected from polypropylene, polyesters, polyethyleneterephthalate, polyamides, Nylon (e.g. Nylon 6 or 6.6), or a polyethylene, e.g. having a density in the range 0.940 to 0.970, or linear low density polyethylene.
  • the second polymeric material B typically comprises a molecularly-oriented polyolefin polymer, such as a polypropylene polymer.
  • the first polymeric material A comprises a thermoplastic polymer or polyolefin or co-polymer.
  • the first polymeric material A can comprise ethylene-propylene co-polymer, polybutylene, polybutene-1 or a co-polymer comprising two or more of butylene, ethylene and propylene, co-polyesters and co-polyamides.
  • the second polymeric material B can be polypropylene and/or the first polymeric material A can comprise an ethylene-propylene co-polymer, a polybutylene such as polybutene-1 or a co-polymer comprising two or more of butylene, ethylene and propylene.
  • the second polymeric material B can be polyester and/or the first polymeric material A can comprise a co-polyester, or the second polymeric material B can be a polyamide and the first polymeric material can comprise a co-polyamide.
  • the first polymeric material A can be thermally compatible and/or autogenously bondable/bonded to/with the second polymeric material B.
  • the second polymeric material B can have a softening point of 10°C or more higher than the softening point of the first polymeric material A.
  • a material or fabric 100 such as a thermoplastic composite material according to an embodiment of the present invention, comprising at least one elongate element 5a to 5d of Figures 1 to 4 .
  • the material or fabric 100 comprises a plurality of (composite) elongate elements 5; 5a to 5d.
  • the material or fabric 100 advantageously comprise a single layer of material or fabric 100.
  • the material or fabric 100 e.g. advantageously single layer of material or fabric, can be consolidated or is consolidatable, e.g. by application of heat and/or pressure.
  • the material or fabric 100 has been found to possibly provide advantages over the prior art, e.g. it has been found that since a single layer of the material or fabric 100 can be heavier than a single layer of single yarn weave of the prior art, whereas in the prior art single layers have been laminated together to provide a suitable material for forming of a product, a single layer of material or fabric 100 of the present invention suffices. This can avoid the need for lamination, so simplifying the manufacturing process and/or obviating and/or mitigating the problem of delamination.
  • the material or fabric 100 can also comprise a plurality of further elongate elements 105, e.g. twisted elongate elements, which are polymeric.
  • the plurality of further elongate elements 100 can beneficially be the same as the plurality of composite elongate elements 5a to 5d.
  • the plurality of composite elongate elements 5a to 5d and plurality of further elongate elements 105 can be mutually interspersed. At least some of the further elongate elements 105 can comprise a material or materials similar or dissimilar to the first polymeric material.
  • Adjacent, e.g. side-by-side, overlaid, cross-laid or intersecting, elongate elements 5a to 5d can be fusible together at least at intersections.
  • Fusing can comprise heating the fabric above the melting temperature of the first polymeric material A, e.g. to a temperature between MP A and MP B .
  • Fusing can comprise cooling the fabric to allow the surface layer to solidify.
  • Fusing the elements can comprise subjecting the fabric to pressure. Fusing can be achieved by single closure press with flat or contoured plates, continuous belt press, induction heated press or via vacuum bagging and autoclaving.
  • Figure 6 shows the fabric 100 after consolidation via a combination of heat and/or pressure.
  • the fabric 100 comprises a woven fabric.
  • the fabric 100 comprises at least one mat of mutually intersecting elongate elements 5a to 5d, 105 fusible together at least at their intersections.
  • the further elongate elements 105 can comprise a single layer or homogenous layer.
  • the further elongate elements 105 can comprise a material or materials similar or dissimilar to the first polymeric material A.
  • the elongate elements 5a to 5d and the further elongate elements 105 are formed as tapes.
  • the elongate elements 20, 25; 5a to 5d comprise one or two surface layers or two opposing surface layers.
  • the material or fabric 100 typically comprises a woven material or fabric.
  • the material or fabric 100 can comprise at least one mat of mutually intersecting elongate elements fusible together at least at their intersections.
  • the thermoplastic material or fabric 100 comprise a consolidated mat or sheet, wherein the plurality of (composite) elongate elements 5a to 5b have been consolidated together, e.g. by application of heat and/or pressure.
  • the fabric or material can be formed without the use of, for example, a resin matrix material, a film or an adhesive.
  • the elongate elements 20, 25; 5a to 5d and/or further elongate elements 105 can selected from tapes, threads, fibres, filaments, strands, or the like.
  • the further elongate elements can comprise a single layer and/or homogenous layer.
  • the further elongate elements can comprise a material or material similar or dissimilar and/or thermally compatible and/or autogenously bondable with the first polymeric material.
  • the elongate elements or members 20, 25; 5a to 5d and the further elongate members 105 can be formed as tapes.
  • the elongate elements 5a to 5d and/or further elongate elements can be woven, knitted, stitched, or can be laid out to form a random fibrous web or may be randomly interspersed to form the material.
  • the elongate elements 5a to 5d and/or further elongate elements 105 can be woven together to form a fabric.
  • the composite elongate elements 5a to 5d and further elongate elements 105 can be woven together to form the fabric or material 100.
  • the warp can be formed of composite or further elongate elements 5a to 5d and the weft may be formed of the other.
  • the warp can be formed of composite elongate elements 5a to 5d and the weft may be formed of further elongate elements 105.
  • the warp can be formed of further elongate elements 105 and the weft may be formed of composite elongate elements 5a to 5d.
  • the further elongate elements 105 can be the same as (i.e. can be identical to) the composite elongate elements 5a to 5d.
  • the composite and further elongate elements can be woven together to form the fabric or material, and the warp and/or the weft may comprise a mixture of composite and further elongate elements.
  • the mixture of composite and further elongate elements can be a random arrangement of composite and further elongate elements.
  • the mixture of composite and further elongate elements can be a regular alternation of composite and elongate elements.
  • warp and weft can comprise, e.g. solely comprise, the composite elongate elements 5a to 5d.
  • the further elongate elements 105 can comprise one or more of: polyesters, polyamides, aramids, thermoplastic polymers, molecularly-oriented thermoplastic polymers, ultra high molecular weight polyalkylenes (UHMWPA), such as ultra high molecular weight polyethylene (UHMWPE) or ultra high molecular weight polypropylene (UHMWPP), multifilament nucleated polypropylenes, and/or carbon fibres.
  • UHMWPA ultra high molecular weight polyalkylenes
  • UHMWPE ultra high molecular weight polyethylene
  • UHMWPP ultra high molecular weight polypropylene
  • multifilament nucleated polypropylenes and/or carbon fibres.
  • the further elongate elements can be formed of hybrid yarns.
  • the hybrid yarns can be formed of at least two different materials or fibres comprising polyesters, polyamides, aramids, thermoplastic polymers, molecularly-oriented thermoplastic polymers, ultra high molecular weight polyalkylenes (UHMWPA), such as ultra high molecular weight polyethylene (UHMWPE) or ultra high molecular weight polypropylene (UHMWPP), multifilament nucleated polypropylenes, and/or carbon fibres.
  • UHMWPA ultra high molecular weight polyalkylenes
  • UHMWPE ultra high molecular weight polyethylene
  • UHMWPP ultra high molecular weight polypropylene
  • multifilament nucleated polypropylenes and/or carbon fibres.
  • the further elongate elements 105 can be formed of hybrid yarns selected from hybrid yarns comprising aramids and UHMWPE or hybrid yarns comprising polypropylene.
  • the further elongate elements 105 can comprise or consist of ultra high molecular weight polyalkylenes selected from UHMWPE or UHMWPP.
  • the laminated material 200 (which is rigid or nondrapable at normal room/ambient temperature) comprises a plurality of layers 205, wherein at least one of said layers 205 comprise the fabric 100.
  • the laminated material 200 comprises two layers 205, e.g. only two layers, or alternatively three layers, e.g. only three layers (see Figure 8 ).
  • each layer 205 comprises the fabric 100.
  • articles i.e. three-dimensional (rigid or self-supporting) articles formed from fabric 100, or alternatively formed from the laminated material 200.
  • the articles 400a to 400d are typically formed by a moulding technique, e.g. press-moulding.
  • the articles 400a to 400d are capable of withstanding relatively high impact, i.e. the articles 400a to 400d have relatively high impact resistance properties.
  • the article 400a comprises a luggage shell, e.g. a shell for a suitcase.
  • the article can comprise or be selected from: a container, an armour product, e.g. body armour, automotive (vehicle) component, sportswear product.
  • the article can be adapted for high impact and/or antiballistic purposes, and/or comprises bulletproof vests, body armour, panels suitable for the protection of military and commercial vehicles, bin liners, blast basket or blast blankets to contain fragmentation debris from the detonation of explosive devices.
  • the article may find use as carpet backing which may be used in automotive or aerospace application or which comprises panels suitable for use on automotive vehicles.
  • the article 400b comprises a toe-cap(s) for protective footwear.
  • the article can comprise connecting straps of handles of intermediate bulk containers or the containers themselves, tarpaulins, packaging, luggage, protective cases, pipes.
  • Figure 12 shows an article 400d comprising an automotive component (e.g. door trim) prior to finishing/trimming.
  • the present invention provides a method of forming a composite elongate element or braid 5, the method comprising:
  • the present invention provides a method of forming a fabric or material 100, such as a thermoplastic (composite) material, the method comprising:
  • Said fabric 100 typically comprises a sheet or mat.
  • Said step of providing can also comprise providing a plurality of further elongate elements 105.
  • Said step of forming comprises weaving.
  • the plurality of composite elongate elements 5a to 5d can comprise warp/weft yarns.
  • the plurality of composite elongate elements can comprise weft/warp yarns.
  • the method further comprises the (subsequent) step of consolidating the fabric 100 by application of heat and/or pressure.
  • the present invention provides a method of forming an article 400, such as a three-dimensional article, comprising the steps of:
  • thermoformed articles are, therefore, less likely to be subject to failure by delamination.
  • the material can be failure averted and utility of the thermoformed parts enhanced.
  • the present invention seeks to provide a solution to one or more issues in the prior art by permitting the ratio of cap layer to be increased beyond that which can presently be realised by coextrusion.
  • the ratio of cap layer may, for example, be effectively tuned to any particular value between 1 and 50% or, indeed, higher.
  • a means is provided for tuning the cap layer ratio anywhere between 1 and 50% or even higher. Any ratio can be achieved by controlling the number of each type of tape or yarn incorporated into the twisting operation and by controlling the relative weight or tex of the at least one B with the at least one A tape or yarn.
  • the solution provides benefits by enhancing the bonding capacity of the twisted tapes or yarns to themselves, or for fabric constructed from said tapes or yarns to bind to itself or to other materials without the need for additional adhesives or films.
  • Articles made from said tapes or yarns or fabrics, whether bonded to themselves or also to other materials, can be made with a tuneable spectrum of properties, e.g. stiffness, delamination strength, impact strength, etc. All of this can be achieved without the need for additional adhesive or film.
  • the breadth of product performance may thus be widened, which may provide a wider range of applications to be served than is possible with current coextruded tape or yarn technology.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Woven Fabrics (AREA)
  • Ropes Or Cables (AREA)
EP19166625.4A 2018-04-12 2019-04-01 Verbesserungen an oder im zusammenhang mit polymermaterialien Pending EP3553213A3 (de)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB1806046.7A GB2569832B (en) 2018-04-12 2018-04-12 Improvements in or relating to polymer materials

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EP3553213A2 true EP3553213A2 (de) 2019-10-16
EP3553213A3 EP3553213A3 (de) 2020-02-26

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GB2492644A (en) 2011-07-04 2013-01-09 Don & Low Ltd Polymer fabrics

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Also Published As

Publication number Publication date
EP3553213A3 (de) 2020-02-26
GB2569832B (en) 2020-10-21
GB201806046D0 (en) 2018-05-30
GB2569832A (en) 2019-07-03

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