TWI537443B - 具有聚合物不織物的多軸防皺布 - Google Patents

具有聚合物不織物的多軸防皺布 Download PDF

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Publication number
TWI537443B
TWI537443B TW100108888A TW100108888A TWI537443B TW I537443 B TWI537443 B TW I537443B TW 100108888 A TW100108888 A TW 100108888A TW 100108888 A TW100108888 A TW 100108888A TW I537443 B TWI537443 B TW I537443B
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Taiwan
Prior art keywords
wrinkle
polymer component
cloth
yarn
fabric
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TW100108888A
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English (en)
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TW201139772A (en
Inventor
羅尼 渥卡茲
Original Assignee
東邦特耐克絲歐洲股份有限公司
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    • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
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    • D04B21/14—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes
    • D04B21/16—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads
    • D04B21/165—Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes incorporating synthetic threads with yarns stitched through one or more layers or tows, e.g. stitch-bonded fabrics
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    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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Description

具有聚合物不織物的多軸防皺布
本發明係關於一種防皺布，其係由至少兩個由複絲強化紗所製得的疊置層構成，其中在複絲強化紗製成之薄層之上和/或之間，防皺布具有至少一層是由熱塑性聚合物材料製得之不織物所製成。
由強化纖維或紗製成之防皺布在市場上早為已知。為此，多軸防皺布經常具有由數個疊置纖維層所製得之結構，其中纖維層係由彼此平行配置之強化纖維薄片所製得。這些纖維層的疊置方式係使得強化纖維層彼此平行定向或交互交叉。這些夾角幾乎都可以調整。然而，通常對於多軸防皺布而言，其角度設定為0°,90°，加或減25°，加或減30°，加或減45°，或者是加或減60°，並且所選擇的結構可使其相對於零度方向上能形成對稱之結構。
可以使用所引述之多軸防皺布織物，係因為其結構特別適合用於複雜構造之製造。因此防皺布沒有將基質材料置於模中，並且被調整成其輪廓。透過這種方式，可獲得一種所謂的預型體，可以在後續將用於製造複合組件所需的基質材料經由灌注或注射的方式引入該預型體中，或者是也透過施加真空的方式。已知的方法為所謂的液體塑模(LM)方法，或是相關之方法，如樹脂轉移塑模(RTM)、真空輔助樹脂轉移塑模(VARTM)、樹脂薄膜灌注(RFI)、液體樹脂灌注(LRI)或是樹脂灌注可撓性工具(RIFT)等方法。
使用這種由強化纖維製成之防皺布所製得的纖維複合組件非常適合直接抵消經由組件之應力方向所引入的力量，因而可以確保高的韌度。有關於纖維密度及纖維角度方面，在多軸防皺布中調適組件中所出現的負載方向可以得到低的比重。
這些疊置的纖維層可以經由數個彼此相鄰配置之縫線或針織線彼此相連及縛牢，並且彼此平行導紗以形成針織紗圈，使得該多軸防皺布得以依這種方式穩定化。這些縫線或針織線因而形成了多軸防皺布的零度方向。這種類型的多軸防皺布可以藉由，例如，標準經編織布機或是縫編機來產生，例如藉由習於本領域領域者已知的LIBA機或Karl Mayer機。藉由縫線或針織線連接之多軸防皺布及其製造曾在例如DE 102 52 671 C1、DE 199 13 647 B4、WO 98/10128或EP 0 361 796 A1中有所描述。
EP 1 352 118 A1揭露了多軸防皺布，其中的強化纖維層係藉由可熔的縫紉紗線固定在一起，其可使得在縫線熔點之上的多軸防皺布具有良好的可成形性以及在後續冷卻期間具有形狀的穩定性。經常使用如聚醯胺或聚酯之類的熱塑性聚合物所製得之縫線，例如如EP 1 057 605號中所揭露。
在US 2005/0164578中曾敘述一種用於複合預型體之前產物，該項前產物具有至少一層由強化纖維編織布料所製得之薄層，並且其中用於穩定化之纖維係整合到至少一層薄層中，這些纖維在增溫的情況下可穩定預型體，並且這些纖維在引入之後將會溶解於基質樹脂中，以產生複合組件。WO 02/16481也揭露了用於(例如)預型體之強化纖維所製成之結構，其中該結構含有可撓的聚合物元件，其係(例如)以纖維的形式被引入強化纖維之間，或者是以縫線的形式將強化纖維彼此連接。該種可撓的聚合物元件包含可溶解於所使用可硬化基質材料之中的材料。
依照DE 198 09 264 A1，其揭露了可以將熱塑性聚合物所製成之黏著性不織物***纖維織物排列的薄層之間，其係彼此縫合並且由強化纖維製成。當溫度被加熱到形成這些不織物之聚合物的熔點以上時，這些熔融黏合之不織物可使得纖維織物排列得以簡單的方式塑形成三維結構，其在冷卻之後仍維持其形狀而不需要復位的力量。
有時為了改善，例如，防皺布的浸漬能力或者是改善，例如，耐衝擊強度，也可以在強化纖維所製得的薄層之間隨機置放一些纖維墊或不織物，或者是定長纖維織物或墊。這種具有像墊子一樣之中間層的多軸防皺布曾在，例如，DE 35 35 272 C2或US 2007/0202762中有所描述，其中在DE 35 35 272 C2中所揭露之不織物或墊，每單位面積之質量數是在100和1200克/平方公尺之間，在US 2007/0202762中，每單位面積之質量數則為40至161克/平方公尺。
EP 1 473 132之主題在於多軸防皺布和生產該多軸防皺布之方法，以及由該多軸防皺布生產之預型體。該文中所描述的多軸防皺布具有由熱塑性纖維製成之中間層，該層係位於單向置放之強化纖維所製得的薄層之間，其中該中間層可以是由雙成分纖維所製得之不織物或者是由混合在一起的不同纖維所製得之混成不織物。形成中間層的聚合物必須與稍晚注入預型體之中的基質樹脂相容。特別是，它說明了在樹脂灌注期間，中間層必須能夠滲透基質樹脂，並且在樹脂灌注期間和之後能夠固定強化層。如果使用環氧樹脂，不織物係由聚醯胺纖維製得。不織物可經由針織針法或是經由熔融黏合與強化纖維製得之薄層相連。
EP 1 772 258也揭露了一種用於製造纖維強化塑膠零件之積層化結構。這些積層化結構具有一個不織物層，其核心層的單位面積質量為100至500克/平方公尺，並且至少有一個表層是由強化纖維所製得。不織物層為例如由支撐體纖維和熱塑性黏合纖維所製成之纖維混合物，並且黏合纖維的熔點低於該支撐體纖維的熔點。在高於黏合纖維熔點及低於支撐體纖維熔點的溫度之下進行熱處理的期間，可完成EP 1 772 258之不織物層的熱強化，因而得到更高內部強度及尺寸穩定性之不織物層。同時，該不織物層在以基質樹脂滲入期間可保證具有高的滲透率。
US 2008/0289743 A1揭露了多軸防皺布，其係由交替配置的強化纖維及不織物薄層所製得，該不織物係由熱塑性纖維所製得，並且係做為中間層，其中該中間層係置放於強化層之間，並且經由針織針法或熔融黏合的方式與其連接。在一個實施實例中，不織物可以由兩種或以上的材料來建構，並且因而混合了不織物或雙成分或三成分之不織物等。依照特殊之實施實例，不織物可由具有核心的核/鞘纖維來製造，其中的核是由聚醯胺製造並且鞘是由聚胺基甲酸乙酯製造。不織物還可用來確保強化纖維單方向排列，並且保證在樹脂滲入期間的樹脂流動。在一個較佳實施實例中，在低於中間層之熱塑性纖維熔點的溫度之下，將會發生硬化。
先前所述舊有技術之複合材料構建方式的缺點是：有相當高比例的材料不是由強化纖維所構成，因此無法對所得之組件貢獻強度。基質材料必須參考強化纖維及不織物有關組件體積方面的總量，使組件中的強化纖維的比例較低，因而導致較低的強度。
EP 1 705 269揭露了一種由聚羥基醚製成的熱塑性纖維材料，其可用於(例如)強化纖維所製造的多軸防皺布中，例如做為強化纖維所製得之薄層之間的不織物。在加熱的情況之下，聚羥基醚材料變的黏稠及膠黏，使得強化纖維在嵌入基質中之前就可以固定成界定的幾何排列方式。接著在高於聚羥基醚纖維材料玻璃轉移溫度的溫度之下，使其完全溶解於基質材料中。
在US 2006/0252334中曾描述由數個強化纖維薄層所製造的防皺布，其在強化層之間含有(例如)由聚合物纖維製得之不織物，以改善這些防皺布所生產之組件的耐衝擊強度。因此，這些聚合物纖維必須能溶於基質樹脂中，依照US 2006/0252334所述，其意味著，與可熔解但不能溶解的熱塑性塑膠相比，其可使得形成這些纖維的聚合物在樹脂基質中得以更均勻的分布。
因為用於US 2006/0252334及EP 1 705 269之織物的聚合物纖維可溶於基質材料中，並且在以基質樹脂滲入防皺布的期間溶解，在組件生產之階段中，無法確保強化層能充分牢牢固定住。
因此，對於防皺布而言存在了一種需求，其係以強化纖維為基，並且在形塑為預型體之後具有良好的懸垂性及尺寸穩定性，並且在基質樹脂滲入期間的良好滲透性。在此同時，由這些防皺布所製造的組件必須擁有高強度的性質，特別是在施加壓力的情況之下，以及高的耐衝擊強度。
因此，本發明的基本目的是提供這種類型的防皺布。
此項目的可經由至少兩個由彼此平行配置之複絲強化紗製得之疊置層所製造的防皺布來達成，其中在複絲強化紗製成之薄層之上和/或之間，防皺布具有至少一層是由熱塑性聚合物材料製得之不織物所製成，並且其中不織物包含第一聚合物成分及第二聚合物成分，其熔點低於強化紗的熔解或分解溫度，其中第一聚合物成分的熔點低於第二聚合物成分的熔點，並且第一聚合物成分可溶於環氧基質樹脂、氰酸酯基質樹脂或苯并基質樹脂中，或者是可溶於這些基質樹脂的混合物中，並且第二聚合物成分不溶於環氧基質樹脂、氰酸酯基質樹脂或苯并基質樹脂中，或者是不溶於這些基質樹脂的混合物中。
第一聚合物具有的熔點較佳是在80至135℃的範圍內，並且第二聚合物成分具有的熔點是在140至250℃的範圍內。
以它的特殊結構為基礎，本發明之防皺布的優異之處在於在預型體中防皺布層的良好懸垂性及固定性、在基質樹脂滲入期間的良好滲透性，以及可以使用它們來製造具有高機械強度和高耐衝擊強度的組件。由於該至少一種不織物係由本發明之聚合物組合所製得，在加熱到第一聚合物成分之熔點的期間，可以使得防皺布層相對於另一層移動。不織物的熔融第一成分扮演著潤滑劑的功能，使得強化紗薄層可以在塑形方法期間在預型體中滑動至所需的位置。在冷卻預型體的期間，第一聚合物成分係發揮熱熔體黏著劑的功能，並且將強化層固定在它們的位置上。
在以基質樹脂後續滲入防皺布結構的期間，其一般係發生在高於第一成分之熔點但低於第二成分之熔點的溫度之下，藉由本發明至少一種不織物之第二聚合物成分的較高熔點，可使得基質樹脂具有良好的滲透性。相反地，第一聚合物成分溶解於基質樹脂中，並且因而失去它在基質樹脂中成為獨立相的完整性。因此，第一聚合物成分的比例因而係與基質材料有關，並且滲入之基質樹脂的比例可以因為第一聚合物成分的比例而降低。結果使得在所得組件中，可設定高的強化纖維體積比例，因而使得械械強度性質得以維持在高的水準。
在本發明防皺布中所使用之不織物可以由具有不同熔點之單成分纖維的混合物所構成，並且可以是一種混合的不織物。然而，該不織物也可以由雙成分纖維(例如核/鞘纖維)所構成，其中纖維的核心是由較高熔點的聚合物所製得，並且鞘是由較低熔點的聚合物所製得。類似於由雙成分纖維所製成之不織物，該不織物也可以由第二聚合物成分所製得之纖維的隨機配置薄層來製造，其中第一聚合物成分係藉由(例如)噴霧或塗布的方式施加於第二聚合物成分之纖維上。塗布可以藉由浸漬第一聚合物成分之分散液或溶液的方式來進行，其中在浸漬之後，將分散液的液體部分或是溶劑予以去除。也可能是由第二聚合物成分製得之纖維所建構的不織物中含有微細顆粒狀的第一聚合物成分，其係嵌在第二聚合物成分的纖維之間。不織物較佳為混合不織物。如果不織物含有比例為2至40重量%之第一聚合物成分及比例為60至98重量%的第二聚合物成分，其已被證明為有利的情況。特佳的是第一聚合物成分的比例在5至35重量%的範圍內，並且第二聚合物的比例在65至95重量%的範圍內。在一個更佳實施實例中，不織物含有比例為20至40重量%之第一聚合物成分及比例為60至80重量%的第二聚合物成分。
在基質樹脂(亦即環氧樹脂、氰酸酯樹脂或苯并樹脂)的硬化溫度之下，第一聚合物成分在較佳實施實例中與硬化基質樹脂經由交聯反應的方式進行化學反應，因而變成均勻基質的整體部分。因此，第一聚合物成分較佳為經由化學交聯反應和環氧基質樹脂、氰酸酯基質樹脂或者是苯并基質樹脂進行反應之聚合物。第一聚合物成分特佳為聚羥基醚。這種類型的聚羥基醚曾描述於(例如)EP 1 705 269中，有關其揭露內容將完整詳細參照。
依照本發明，第二聚合物成分的熔點比第一聚合物成分的熔點高。第二聚合物成分較佳係在所使用基質樹脂的硬化溫度下熔解，或者是在第一聚合物成分的熔點和基質樹脂的硬化溫度之間範圍的溫度下熔解。依照這種方式，第二聚合物成分可能會與基質材料黏合；然而，不同於第一聚合物成分，其將在硬化的基質樹脂中形成自己的相。在硬化期間及在後續組件中，第二聚合物成分所形成的相將有助於限制裂隙蔓延，因而可對於耐衝擊強度的提升具有決定性的貢獻。
至於本發明之防皺布所使用之不織物的第二聚合物成分，可使用一般被製成熱塑性纖維之聚合物，只要它們能符合所主張的要求即可，例如聚醯胺、聚醯亞胺、聚醯胺-醯亞胺、聚酯、聚丁二烯、聚胺基甲酸乙酯、聚丙烯、聚醚醯亞胺、聚碸、聚醚碸、聚苯碸、聚苯硫、聚醚酮、聚醚醚酮、聚芳醯胺、聚酮、聚酞醯胺、聚苯醚、聚對酞酸丁二酯或聚對酞酸乙二酯，或者是這些聚合物之共聚物或混合物。
就先前引用的基質樹脂而言，較佳的情況是第二聚合物成分為聚醯胺均聚物或聚醯胺共聚物或者是由聚醯胺均聚物和/或聚醯胺共聚物所製得之混合物。特佳為該聚醯胺均聚物或聚醯胺共聚物為聚醯胺6、聚醯胺6,6、聚醯胺6,12、聚醯胺4,6、聚醯胺11、聚醯胺12，或是以聚醯胺6/12為基質之共聚物。
關於橫跨防皺布厚度方向之材料特性的均質化方面，較為有利的狀況是不織物層係安排於本發明之防皺布的每一層複絲強化紗所製得的薄層之間。在使用本發明之防皺布所生產之組件特色方面及在其機械特性儘可能的高水準方面，可能的較佳情況是不織物具有的單位面積質量是在5至25克/平方公尺的範圍內。特佳的是單位面積質量在6至20克/平方公尺的範圍內。
在本發明之防皺布中，可以使用一般用來製造纖維強化複合材料的強化纖維或紗線來做為強化纖維。複絲強化紗較佳為碳纖維、玻璃纖維、或芳醯胺紗，或者是高級UHMW聚乙烯紗，並且特佳為碳纖維紗。
有關所得組件之機械特性的高水準方面，較佳是強化紗彼此之間平行排列並且與複絲強化紗所製得之薄層一起平行相鄰。藉由這種方式，可以達到高的纖維體積比例，並且在該組件中可避免低纖維比率的區域。
在一個還要更佳的實施實例中，當垂直觀看薄層平面時，疊置層的強化紗之間彼此形成一個角度。藉由這種方式，可以相對於後續組件的應力方向進行強化紗方向的適應調節，並且確保在這些應力方向上具有所需之強度。因此，如果強化紗的薄層以相對於零度方向為固定夾角的方式交替的話，是較為有利的，並且可形成一種對稱或準等向的結構。因此，本發明之防皺布可以(例如)具有一種具有+45°、-45°、+45°及-45°薄層之結構，亦即，其中在各別薄層之內單方向排列之強化紗相對於零度方向具有+45°、-45°、+45°及-45°之夾角。通常，這種類型之多軸防皺布的夾角α是在±20°至大約±80°的範圍內。典型的夾角α為±25°、±30°、±45°及±60°。
同時為了在後續組件中能容納(例如)進一步要求的應力方向，本發明之防皺布較佳是也包括複絲強化紗的薄層，其中該強化紗相對於零度方向形成0°的夾角和/或包括相對於零度方向形成90°夾角的強化紗薄層。這些0°和/或90°之薄層較佳係位於以α角度定向的薄層之間。然而，也可能是具有以下方向之結構：90°、+30°、-30°、0°、-30°、+30°、90°，亦即外層為90°薄層形成之結構。
在本發明之防皺布中，複絲強化紗的薄層亦可由預先製造的單向編織織物所構成，該編織織物係由複絲強化紗所製成。對於這些單向編織織物而言，在每一個例子中，彼此平行排列並且形成薄層之強化紗係藉由鬆散綁紮線製成之鏈來彼此連接，其主要係橫向延伸至強化紗。這種類型的單向織物在(例如)EP 0 193 479 B1或EP 0 672 776號中有所描述，有關其揭露內容將完整詳細參照。
為了維持本發明防皺布的更高穩定性，特別是在樹脂注入期間，並且(例如)避免強化層的滑動，在本發明的較佳實施實例中，由複絲強化紗及至少一層不織物層所製成的薄層係藉由形成針織紗圈或環圈之縫線或縫編線使之彼此相連接及彼此固定，並且以針步寬度的距離彼此分離。因此，縫線界定出防皺布的零度方向。
因此，由複絲強化紗所構建之本發明防皺布的各個單獨薄層可以藉由標準的方法及設備來生產，並且相對於零度方向以固定的角度來疊置。如同先前解釋過的，在本領域已知的機器為LIBA機或Karl Mayer機。藉由這種方式，強化紗也可以彼此鄰接的方式定位於薄層內，亦即它們可以無間隙的方式相鄰。
通常用來製造紗線防皺布之紗線被認為可用來做為縫線。在本發明的背景說明中，縫線也被認為並非經由縫紉而是經由其它形成針織紗圈或環圈的紡織方法(特別是經由針織方法)併入本發明多軸防皺布中的一種線。經由針織紗圈可使得縫線將多軸防皺布的薄層彼此連接，而針織紗圈可具有常用於多軸防皺布的梭織類型，如稜紋針織(tricot knit)或花邊梭織(fringe weave)。其中以花邊梭織為較佳。
縫線較佳為複絲紗線。在後面的樹脂注入程序期間，所使用的縫紉紗線可以(例如)在高於樹脂注入溫度但低於所使用樹脂之硬化溫度的溫度下熔解。這些紗線也可以在硬化溫度下熔解。縫紉紗線也可以是能在(例如)注入期間或者是在樹脂硬化期間溶解於基質樹脂中的類型。這種類型的縫線在(例如)DE 199 25 588、EP 1 057 605或US 6 890 476中有所描述，有關其揭露內容將完整詳細參照。縫線較佳係由聚醯胺、聚芳醯胺、聚酯、聚丙烯酸酯、聚羥基醚或是這些聚合物之共聚物所構成。這些縫線特佳係由聚酯、聚醯胺或聚羥基醚或這些聚合物之共聚物製得的複絲紗線所構成。
如果縫線在室溫下具有≧50%的斷裂伸長度是較為有利的。這是因為高的斷裂伸長度可以使得本發明之多軸防皺布的懸垂性改善，這意味著可以實現更複雜的結構或組件。
在本發明之車縫或針織防皺布的一個特殊實施實例中，縫線的線密度是在10至35分特克斯(dtex)的範圍內。也就是說，如果防皺布縫線的線密度在所述範圍內時，關於壓縮負載的穩定性方面特別會呈現出明顯的改善。此係歸因於，相較於已知的多軸防皺布，由於使用這種類型的縫線，而使得各別纖維層的纖維結構被明顯均質化。特別是，已確定強化紗的纖維與舊有技術之防皺布的情況相比其將呈現出更直的緯圈(course)。縫線具有的線密度特佳是在10至30分特克斯的範圍內，線密度還要更佳是在15至25分特克絲的範圍內。
如同解釋過的，縫線形成針織紗圈或環圈並且界定出防皺布的零度方向。如果這些薄層的強化紗係相對於防皺布的零度方向對稱配置，並且相對於它們的延伸方向，與零度方向間形成一個夾角α時，該角度不等於90°也不等於0°，在使用本發明之多軸防皺布所生產複合組件的壓縮負載和/或衝擊負載的韌度方面，另一項驚人的發現是，如果由縫線所形成之針步的針步長度s係由針步寬度w以及本發明之多軸防皺布中之強化紗的夾角α1來決定，並且須滿足(I)和(II)的關係時，其可以達到特別良好等級的韌度：
且
其中乘數B可以假設在0.9B1.1的範圍內，並且n可以假設為0.5,1,1.5,2,3,或4之數值，對於小數值的w‧|tanα1|/2.3而言，針步長度s係介於方程式(I)所示的範圍內。針步寬度w，亦即縫線之間的距離係以毫米為單位來表示。
角度α1被認為是相對於零度方向的夾角，當由上方俯視時，多軸防皺布第一層的強化紗的排列方式係使得強化紗與零度方向呈現90°及0°的差異。如果多軸防皺布最頂層的強化紗對於零度方向具有90°或0°的夾角，則在這些層下方所配置的第一層被視為具有不同於90°及0°夾角的強化紗。
在檢視纖維結構時，亦即防皺布薄層中的複絲強化紗之纖維或絲的緯圈，結果發現，藉由遵守(I)和(II)之關係式可得到非常平整的纖維緯圈，其具有明顯降低波紋的紗線及明顯降低紗線束之間外觀的間隙。基於此，重要的是沿著紗線束或纖維股之緯圈，縫線在纖維股寬度方向上的不同位置上刺穿纖維股。如設定之針步長度和針步寬度的數值落在(I)和(II)之關係式所界定的範圍之外時，通常會觀察到沿著強化紗延伸部分之縫線的貫穿基本上會發生在該線或纖維絲之間或者是纖維股或強化紗的區域之間。此將導致紗線緯圈中明顯的波紋或起伏，並且導致在纖維絲之間形成間隙。
整體而言，經研究發現，當使用具有低線密度之較佳縫線且當符合上述關係式(I)和(II)時，由強化紗薄層的上方俯視，縫線在防皺布中的刺穿點所造成之纖維撓曲，亦稱為起伏角(undulation angle)，可以降低高達約25%。在此同時，所造成的起伏區域，亦即纖維絲或線呈現出撓曲的區域或範圍，可以降低約40%，並且纖維之間的自由空間(其將導致區域具有較高樹脂比例及降低組件的韌度)因而被明顯地降低(特別是在壓縮負載的情況之下)。
在此同時，參考以本發明多軸防皺布為基的複合積層之顯微圖片，可以觀察到，使用具有低線密度之較佳縫線，令人驚訝的，在平行於強化紗薄層延伸部分及垂直於強化紗延伸部分的觀察方向上，可以使強化線的緯圈明顯的均質化。因此，藉由使用線密度為23分特克斯之縫線，可以使得強化紗之纖維絲實質上為直線緯圈。如果使用之縫線具有的線密度在此較佳範圍之外時，例如48分特克斯，當觀看所述複合積層的橫截面時，所有的纖維絲呈現出非常不規則、具有變動振幅之波浪狀緯圈，該振幅的等級為一層強化線之厚度的大小。
針步長度可在2毫米至4毫米的範圍內。當針步長度大於4毫米時，將無法確保本發明之防皺布具有足夠之穩定性。相反的，低於2毫米時，在防皺布中將出現相當高數目的瑕疵。此外，多軸防皺布的生產經濟價值也會大幅降低。
本發明之防皺布因為具有良好的懸垂性及良好的樹脂滲透性而顯得相當獨特。此外，它們生產出的組件能夠具有抵擋壓縮負載的高穩定性以及對衝擊負載具有高容忍性。因此，它們特別適合生產所謂的預型體，由該預型體可以製造出更複雜的纖維複合組件。因此，本發明特別是尚與用於製造纖維複合組件之預型體有關，其含有本發明之防皺布。

Claims (15)

  1. 一種防皺布，其係由至少兩個由彼此平行配置之複絲強化紗所製得的疊置層構成，其中在複絲強化紗製成之薄層之上和/或之間，防皺布具有至少一層是由熱塑性聚合物材料製得之不織物所製成，並且其中不織物包含第一聚合物成分及第二聚合物成分，其熔點低於強化紗的熔解或分解溫度，其中第一聚合物成分的熔點低於第二聚合物成分的熔點，並且第一聚合物成分可溶於環氧基質樹脂、氰酸酯基質樹脂或苯并基質樹脂中，或者是可溶於這些基質樹脂的混合物中，並且第二聚合物成分不溶於環氧基質樹脂、氰酸酯基質樹脂或苯并基質樹脂中，或者是不溶於這些基質樹脂的混合物中。
  2. 如申請專利範圍第1項之防皺布，其中第一聚合物成分具有的熔點是在80至135℃的範圍內，並且第二聚合物成分具有的熔點是在140至250℃的範圍內。
  3. 如申請專利範圍第1或2項之防皺布，其中不織物為混合不織物。
  4. 如申請專利範圍第1或2項之防皺布，其中第二聚合物成分為聚醯胺均聚物或聚醯胺共聚物或者是聚醯胺均聚物和/或聚醯胺共聚物之混合物。
  5. 如申請專利範圍第4項之防皺布，其中聚醯胺均聚物或聚醯胺共聚物為聚醯胺6、聚醯胺6,6、聚醯胺6,12、聚醯胺4,6、聚醯胺11、聚醯胺12，或是以聚醯胺6/12為 基質之共聚物。
  6. 如申請專利範圍第1或2項之防皺布，其中當環氧基質樹脂、氰酸酯基質樹脂或苯并基質樹脂被交聯時，第一聚合物成分為與這些基質樹脂進行化學反應的一種聚合物。
  7. 如申請專利範圍第6項之防皺布，其中第一聚合物成分為聚羥基醚。
  8. 如申請專利範圍第1或2項之防皺布，其中不織物含有比例為2至40重量%之第一聚合物成分及比例為60至98重量%的第二聚合物成分。
  9. 如申請專利範圍第1或2項之防皺布，其中至少一個不織物層所具有的單位面積質量是在5至25克/平方公尺的範圍內。
  10. 如申請專利範圍第1或2項之防皺布，其中不織物層係安排於每一個複絲強化紗之薄層之間。
  11. 如申請專利範圍第1或2項之防皺布，其中複絲強化紗為碳纖維、玻璃纖維、或芳醯胺紗，或者是高級UHMW聚乙烯紗。
  12. 如申請專利範圍第1或2項之防皺布，其中當垂直觀看薄層平面時，疊置層的強化紗之間彼此形成一個角度。
  13. 如申請專利範圍第1或2項之防皺布，其中由複絲強化紗及至少一層不織物層所製成的薄層係藉由彼此平行 且彼此分離的縫線使彼此相連接。
  14. 如申請專利範圍第13項之防皺布，其中在一層以及鄰近薄層之內的強化紗係彼此相連並且藉由以w的針步寬度彼此分離之縫線彼此縛牢，其中縫線形成具有s針步長度之針步，並且防皺布的零度方向係由縫線來界定，其中薄層的強化紗相對於防皺布的零度方向為對稱配置，並且相對於它們的延伸方向，與零度方向間形成一個夾角α，該角度不等於90°也不等於0°，其中縫線的線密度是在10至35分特克斯(dtex)的範圍內，其中縫線的針步長度係由針步寬度以及強化紗的角度α1來決定，並且須滿足(I)和(II)的關係： 其中w=針步寬度[毫米]0.9B1.1並且n=0.5,1,1.5,2,3，或4,並且其中角度α1被認為是相對於零度方向的夾角，當由上方俯視時，多軸防皺布第一層的強化紗的排列方式係使得強化紗與零度方向呈現90°及0°的差異。
  15. 一種用於製造複合組件之預型體，其中其包含如申請專利範圍第1至14項中一或多項之防皺布。
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