TWI388429B - 用於芯型複合物與芯型複合結構之強化芯材的製造方法 - Google Patents

用於芯型複合物與芯型複合結構之強化芯材的製造方法 Download PDF

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TWI388429B
TWI388429B TW095113987A TW95113987A TWI388429B TW I388429 B TWI388429 B TW I388429B TW 095113987 A TW095113987 A TW 095113987A TW 95113987 A TW95113987 A TW 95113987A TW I388429 B TWI388429 B TW I388429B
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Matthias Alexander Roth
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Evonik Roehm Gmbh
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    • B29C70/06—Fibrous reinforcements only
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    • 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
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Description

用於芯型複合物與芯型複合結構之強化芯材的製造方法
本發明係關於強化元件的設計和製造，其根據申請專利範圍第1項的內容係橫穿芯型複合物的厚度以強化芯型複合結構。
本發明適合用來強化芯型複合結構。該芯型複合結構可較佳地包括帶有紡織半成品芯層之纖維－塑膠複合物(圖1；3和5，例如編織物或搓織物，帶，等)，芯材(圖1；4，例如聚合物發泡體)及聚合物基質材料(熱塑性或熱固性材料)。芯型複合為經由一層接一層所組建的結構且包括相當薄的上複蓋層(圖1；3)和下覆蓋層(圖1；5)以及具低表觀密度的相當厚芯層(圖1；4)。
藉由本發明，芯型複合結構的橫向性質(例如z方向的壓縮或張力剛度及強度，xz和yz平面中的剪切剛度和強度，在覆蓋層與芯層之間的抗剝離性，破損安全性能)以及平面內機械性質(例如在片材面方向中的剛度和強度)都可借助橫穿厚度的強化元件獲得明顯的增加。
用於沿彼等的厚度方向強化芯型複合結構之所有先前已知製造方法，諸如雙鞍型縫連，盲縫或雙針縫連技術與簇絨法(tufting method)，都具有下述共同特色：強化元件(例如縫線，粗紗)都是與針一起導到芯型複合結構中。於習用的似紡織品縫紉材料的情況中，包括縫線的針之穿透及隨後縫針的拉出和留下縫線於縫口中之程序通常就紡織品的回彈性效應而言不會呈現任何問題。不過，在以聚合物硬質發泡體作為芯材的芯型複合結構的情況中，包括縫線的針之穿透會造成泡孔結構被破壞及聚合物硬質發泡體因塑性和彈性形變的結果變形到縫針直徑之尺寸。
在縫針拉出及縫線留在縫孔之後，會因泡孔壁的彈性形變成分而使穿孔縮小，由是芯孔直徑再度變得比縫針直徑更為小(參閱圖2)。在所得芯層中穿孔直徑與所用縫針直徑之間有幾乎線性相關性(圖2)，亦即，縫針直徑愈大，所得芯層中的穿孔也愈大。再者，縫線會造成芯孔直徑的額外拓寬。此種額外拓寬大約對應於縫線的橫截面積(圖2)。此處也會有下述情況：所用縫線的橫截面積愈大，該額外拓寬就愈大。
在用液體基質材料浸漬該芯型複合結構且隨即予以固化之後，芯孔直徑及縫線的纖維體積含量可利用顯微鏡檢驗予以測定。對於利用雙鞍縫型縫連技術及使用直徑1.2毫米的縫針和62克/公里的線重之聚芳醯胺線(aramid thread)縫出的芯型複合結構所作實驗性檢驗於此顯示出在芯材中所得樹脂柱的直徑(約1.7毫米)大於單插縫情況中未浸漬芯型複合結構的測定出之芯洞直徑(約1.1毫米；比較圖2和3)。此事實之理由縫針直徑區內的毗鄰泡孔壁被縫針***所破壞。於隨後的浸入程序中，樹脂可能穿透入此等區，隨後使孔泡更打開成為具有0.7毫米半徑(圖4)。
在使用雙鞍縫型縫紉技術時，隨著每一插針，總有二條縫線沿著芯型複合結構的z方向被導入(參閱圖4和5)。為了增加在一穿孔中的縫線體積含量，及隨後的強化效應，可在已縫處再縫入一或更多次。不過，已在芯洞中的縫線可能被縫針的重新***所損壞。借助於顯微鏡檢查，可以確定縫線體積含量不會如預料地隨插針數目呈比例地增加(圖3，4和5)。此事實之原因在於芯洞直徑不會隨插針數目和導入的縫線數之增加而保持固定，因為芯洞直徑會因額外的縫線導入增加大約縫線橫截面積之故(圖3，虛線)。不過，同樣確定者，只有在非常高插針數之時，真正的曲線輪廓(圖3，實線)才會遵循此理論。相異地，在只有小數目插針時，芯洞直徑會增加到不成比例地大程度。其原因在於縫機的定位準確性。若要再次縫入的位置再度移開，則縫針不會準確地插到已存在的洞孔之中央而會在定位準確度的限制內，偏移少許，由是芯孔會不成比例地增加。在插到相同芯洞中約8次之後，該洞孔已被拓寬到使縫針進入既有洞孔中不會進一步破壞泡孔壁之程度。在繼續***之下，該拓寬只會被導入的額外縫線之結果而發生。於圖4和5中顯示出隨著芯洞中縫線數目的增加，縫線體積含量的可能增加情形。圖4中的黑色曲線描述中在固定的芯洞直徑下，縫線體積含量的成比例增加，而虛線－點曲線係根據前述正確定位準確度及因導入縫線結果使芯洞直徑額外拓寬之理論予以描述者，因點線係描述隨縫線或***數目增加所致縫線體積含量的真正走勢。於單一***的情況中，可達到僅約3.2%的纖維體積含量，其經由***到多達10次僅增加到約20%(參閱圖4和5)。相異地，單縫線股的纖維體積含量為約58%(參閱圖5)。
從此等檢驗明顯可知在使用習用製造方法(例如雙鞍縫型縫紉技術)時在聚合物芯材中所得直徑主要決定於所用的縫針直徑，縫線橫截面積及所用聚合物硬質發泡體的核心直徑。由於在所有先前已知的強化方法之情況中，縫針與縫線係同時插到芯型複合結構中，因此在導入的強化元件橫截面積與芯洞直徑尺寸之間總會有不利的關係。因此之故不能用傳統強化法達到高的芯洞直徑中之纖維體積含量，相似地高到芯層的纖維體積含量(大於50%)。不過，由於機械性質主要受到所導入的高剛度和高強度強化元件所影響，因此目標必須驅向於使芯洞直徑中強化物的纖維體積含量儘可能地高。再者，芯洞直徑中的高樹脂成分會促成重量的增加，此在航太領域中特別會不可忍受者。
 目的
本發明係基於下述目的：經由在芯型複合結構的厚度方向(z方向)摻入強化元件，於達到高的在芯洞直徑中強化元件之纖維體積含量的可能性下，改良芯型複合結構的機械性質。再者，不會因為芯型複合結構中摻入強化元件而不利地影響重量太多。此種新穎縫合技術同樣地可用未實施及固定額外的結構組件(例如，繩索或框，等)到芯型複合結構。
解決之道
該目的係經由下述而達成，在芯材中導入所需穿孔及彼此不同次數地進行強化結構物之導入，由是可經由所用縫線的橫截面積調整芯洞直徑內強化物的纖維體積含量。圖1以圖解說明由此一方式強化的芯型複合結構之基本發明和設計。一挾具系統(2)從芯型複合結構的一側進行單向***(步驟1和2)到芯材(4)之內且隨意地穿過上紡織品覆蓋層(3)與下紡織品覆蓋層(5)(步驟2)，且藉助一挾具(1)，在相反側上挾取由一裝置(7)所供給的強化結構物(6)，例如，縫線、拉擠纖維－塑膠－強化棒(步驟2)，且在回移中將該強化結構物導到芯型複合結構中(步驟3)。於後續程序步驟中，挾具系統(2)向上移且將強化結構物抽引到芯材或芯型複合結構中(步驟3)。
可以使用聚合物硬質發泡體(例如PMI、PVC、PEI、PU等)作為芯材(4)。芯材(4)可具有高達150毫米之厚度，約1250毫米之寬度及2500毫米之長度。上紡織品覆蓋層(3)和下紡織品覆蓋層(5)可構造成相同或不同者且以玻璃、碳、聚芳醯胺或其他強化材料所組成。個別紡織品覆蓋層的厚度可相同或不同且介於0.1毫米與1.0毫米之間。可以使用熱塑性或熱固性材料作為聚合物基質材料。
強化結構物(6)可包括紡織品強化結構物(例如，縫線、粗紗)或棒形元件(例如單向纖維－塑膠複合物針，單向塑膠針或金屬針，等)。強化結構物(6)的典型直徑可為0.1毫米至2.0毫米。
於後續程序步驟中，將縫材或強化單位進一步傳送到下一插置位置且於該處重複該強化程序。此外，所供給的強化結構物可等長裁切，使得在一插置與另一插置之間沒有聯結。等長裁切可用所有習用的技術手段來實施，諸如機械切割或火陷燒斷。強化結構物的抽入可能造成由挾具系統***所得芯洞直徑的額外拓寬，由是可實現高度纖維體積含量。由於強化元件係由拉力導引到芯型複合結構內或只到芯材內，因此可得該強化結構物的很好的排列且沒有皺曲。藉助此種強化方法，摻入的強化元件同樣可在純橫向刀的負載之下，具有相對於Z軸為0°以外之角度，例如＋/－45°。
根據本發明在彼等的厚度方向中強化的芯型複合結構可以用在運輸領域中，諸如航太、汽車及鐵道車構造及造船，而且也可用來運動和醫學領域以及建築業中。
於強化程序之後，可將芯型複合結構用熱固性或熱塑性基質材料以液體－複合物模製法予以浸漬。
1．．．挾具
2．．．挾具系統
3．．．上紡織品覆蓋層
4．．．芯材
5．．．下紡織品覆蓋層
6．．．強化結構物
7．．．供給強化結構物(6)所用裝置
圖1：根據本發明的芯型複合結構之基本設計。
圖2：使用雙鞍縫型縫合技術時在單***情況中所得縫針直徑對芯洞直徑之影響。
圖3：使用雙鞍縫型縫合技術時，使用帶有縫線的1.2毫米直徑縫針所得插針數目與芯洞直徑之間的相關性。
圖4：使用雙鞍縫型縫合技術所得樹脂柱機構及一芯洞內的縫線體積含量對芯洞中縫線數目的關係。
圖5：使用雙鞍縫型縫合技術時，在插針數或縫線數與芯洞內的纖維體積含量之間的關係。
1．．．挾具
2．．．挾具系統
3．．．上紡織品覆蓋層
4．．．芯材
5．．．下紡織品覆蓋層
6．．．強化結構物
7．．．供給強化結構物(6)所用裝置

Claims (9)

  1. 一種用於芯型複合物之強化方法，其特徵在於令挾具系統(1，2)從結構的一側***聚合物發泡體芯材(4)或有施加覆蓋層(3，5)的該聚合物發泡體芯材，到另一側挾取強化結構物(6)，且經由向後移動，將該強化結構物(6)導入該聚合物發泡體芯材(4)或有施加覆蓋層(3，5)的該聚合物發泡體芯材。
  2. 如申請專利範圍第1項之用於芯型複合物之強化方法，其中該強化結構物(6)包含呈棒狀形式的似紡織品強化結構物或元件。
  3. 如申請專利範圍第1或2項之用於芯型複合物之強化方法，其中該覆蓋層(3，5)係由紡織半成品所組成，該聚合物發泡體芯材(4)係由聚合型或結構化芯材所組成，且其中該覆蓋層、該芯材及該強化元件係經嵌置於聚合物型基質材料內。
  4. 如申請專利範圍第1或2項之用於芯型複合物之強化方法，其中該強化結構物(6)在被導入該聚合物發泡體芯材(4)或有施加覆蓋層(3，5)的該聚合物發泡體芯材之後未經等長裁切。
  5. 如申請專利範圍第1或2項之用於芯型複合物之強化方法，其中該強化結構物(6)在被導入該聚合物發泡體芯材(4)或有施加覆蓋層(3，5)的該聚合物發泡體芯材之後 經等長裁切。
  6. 一種芯型複合物，其可由如申請專利範圍第1-5項中任一項之用於芯型複合物之強化方法所製得。
  7. 一種如申請專利範圍第6項之芯型複合物之用途，其係用於太空船、航空器、海陸航器及鐵軌車的製造。
  8. 一種如申請專利範圍第6項之芯型複合物之用途，其係用於運動設備的製造。
  9. 一種如申請專利範圍第6項之芯型複合物之用途，其係用於內部、產業及外部構造所用結構元件的製造。
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