+

WO2001092002A2 - Agregation de fibres de carbone a orientation aleatoire et mise en forme d'une paraison de fibres de carbone - Google Patents

Agregation de fibres de carbone a orientation aleatoire et mise en forme d'une paraison de fibres de carbone Download PDF

Info

Publication number
WO2001092002A2
WO2001092002A2 PCT/US2001/017983 US0117983W WO0192002A2 WO 2001092002 A2 WO2001092002 A2 WO 2001092002A2 US 0117983 W US0117983 W US 0117983W WO 0192002 A2 WO0192002 A2 WO 0192002A2
Authority
WO
WIPO (PCT)
Prior art keywords
carbon fiber
layers
binder
fibers
carbon
Prior art date
Application number
PCT/US2001/017983
Other languages
English (en)
Other versions
WO2001092002A9 (fr
WO2001092002A3 (fr
Inventor
Mark Sloan
Richard D. Blackmore
William M. Lepola
Original Assignee
Ihc Rehabilitation Products
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 Ihc Rehabilitation Products filed Critical Ihc Rehabilitation Products
Priority to AU2001284641A priority Critical patent/AU2001284641A1/en
Publication of WO2001092002A2 publication Critical patent/WO2001092002A2/fr
Publication of WO2001092002A3 publication Critical patent/WO2001092002A3/fr
Publication of WO2001092002A9 publication Critical patent/WO2001092002A9/fr

Links

Classifications

    • 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
    • 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
    • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
    • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
    • B29C70/24—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
    • 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
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/50—Shaping or impregnating by compression not applied for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
    • 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
    • B32B5/06—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
    • 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
    • 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
    • D04H1/4218—Glass 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
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • 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
    • D04H1/4282—Addition polymers
    • D04H1/43—Acrylonitrile series
    • 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
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • 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
    • D04H1/4326—Condensation or reaction polymers
    • D04H1/4334—Polyamides
    • D04H1/4342—Aromatic polyamides
    • 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
    • D04H1/48—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 in combination with at least one other method of consolidation
    • 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
    • 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
    • B32B2262/0253—Polyolefin 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide 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
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0261—Polyamide fibres
    • B32B2262/0269—Aromatic polyamide 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
    • B32B2262/02—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
    • B32B2313/00—Elements other than metals
    • B32B2313/04—Carbon
    • 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
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • 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
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • 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
    • B32B2377/00—Polyamides

Definitions

  • the present invention relates to a method for consolidating a layer of carbon fibers with carrying or covering layers of non- woven fibers.
  • the present invention also relates to a method for producing a carbon fiber preform part that is used to form a finished part; and more particularly, this invention relates to a novel method for applying pressure and heat to a random arrangement of carbon fibers consolidated with a binder to produce a preform part.
  • carbon fibers are made from either acrylic- based woven precursors, or petroleum by products.
  • Acrylic-based fibers are referred to as pan
  • petroleum-based fibers are referred to as pitch.
  • Finished products made from pitch tend to cost more because it takes more equipment and time to produce the finished product.
  • the raw material costs for pitch are less than the raw material costs for pan.
  • Pan and pitch carbon fibers were first used by the aerospace industry for high strength, lightweight application where fiberglass and similar reinforcement were insufficient. However, the price for both types of carbon fiber was high since only limited quantities were produced. More recently, the use of carbon fibers has expanded into the engineered composite industry, for example golf club shafts, tennis rackets, bicycles, motorcycles, marine and certain automotive applications. Traditionally, carbon fiber is produced in continuous filament bundles that can then be milled and chopped into short- length fibers. The continuous filament bundles and short-length fibers are then packaged for shipment to fabricators. The fabricators, which include those who weave, stitchbond, braid, knit and needlepunch, manufacture the product into the roll good forms identified above for shipment to finished part manufacturers. The product follows the traditional manufacturing steps from raw material to work in progress to finish goods.
  • carbon fibers have been produced as random carbon filaments with a diameter of about 10 microns in either a lofty batt or mat configuration.
  • the rough product is characterized by a random arrangement of carbon filaments, with lengths of approximately three inches to twenty four inches, oriented predominantly in the machine or longitudinal direction.
  • the product is mechanically unstable and difficult to handle in this form and requires some type of post-production treatment.
  • a chemical (“wet - hydro-entanglement”) or physical (“air lay”) consolidation method has been used historically to effectively entangle the fibers and, with the addition of a chemical binding agent, stabilize the carbon fibers.
  • a new carbonization process produces an arrangement of carbon fiber with boundaries roughly defining a sheet, which is referred to as batt.
  • Batt is relatively inexpensive to produce and is characterized by a random arrangement of carbon fiber filaments in the machine or longitudinal direction. This means that filaments are positioned longitudinally but randomly arrayed throughout the sheet. As a result of the random arrangement in the machine direction, batt is a high-loft product, meaning that the interstice or space between the intersection of the filaments is measurable.
  • Each carbon filament has a fiber length greater than 3.0 inches and a diameter in the 8.0-15.0 micron range.
  • carbon fiber batt has a low mass and is structurally unstable. As a result, the commercial utility of batt has been limited to applications where fiber orientation and stability is not critical, such as insulation.
  • batt suffers from poor handling characteristics.
  • Previous attempts have been made to increase the structural stability of batt and facilitate handling of the product.
  • a backing structure can be chemically adhered to the batt, or a disposable carrier sheet can be secured to the batt.
  • These additions have failed to increase the structural stability of the batt because neither the backing structure nor the carrier sheet provides uniformity in the carbon fiber orientation and density.
  • other traditional methods such as stitch-bonding or needle-punching, are applied to batt, the actual carbon fiber filaments are severely damaged and both physical and mechanical properties can be adversely affected.
  • a method of forming a composite including a carbon fiber layer surrounded by at least a single layer of non- woven fibers both above and below the carbon fiber layer is disclosed.
  • the layer(s) of carbon fiber and the layers of non- woven fibers are consolidated with a unique needle-punching method.
  • the layer(s) of carbon fiber and the layers of non- woven fibers are consolidated with a stitching method.
  • the present invention also relates to a method for producing a carbon fiber preform part with increased structural stability that can be used to form a finished part. The increase in structural stability is achieved by use of a chemical or thermoplastic binder applied to, or in intimate contact with, the carbon fiber.
  • pressure is applied to a random arrangement of carbon fibers consolidated with a binder.
  • a high solubility binder comprising a polyester based polyurethane dispersion, such as available from Bayer AG can be used.
  • Typical binder compositions may also include coupling agents, lubricants, emulsifiers and conductivity increasing additives that are dissolved or dispersed in water or ' a solvent.
  • Thermally activated binders may also be used comprising one or more cross-linkable, film forming polymers which when crosslinked or cured, become insoluble.
  • the binder stabilizes the carbon fibers in the arrangement but allows the arrangement to remain pliable. Heat is then applied to the arrangement to set the binder and form a preform part.
  • the disclosed method improves the electrical continuity and conductivity of the preform part without damaging the internal carbon fibers.
  • pressure is applied to a composite structure formed from the combination of a layer or randomly arranged carbon fibers and layers of pre-consolidated materials combined with a binder. Heat is then applied to the composite structure to set the binder and form a preform part.
  • pressure is applied to a composite structure formed from the combination of a layer of randomly arranged carbon fibers and layers of pre-consolidated materials.
  • a binder is then infused into the composite structure and heat is applied to set the binder and form a preform part.
  • This suspension impregnation process utilizes vacuum to infuse the binder and further employs the vacuum to remove byproducts of the binder processing (i.e. water vapor, volatiles).
  • a low melting temperature binder yarn or filament may be used in the preforming process.
  • These filaments are typically spun from polymers such as nylon, polypropylene, polyethylene or polyester.
  • These low melt polymer filaments can be combined or interlaced with the carbon fibers using conventional methods such as hydroentanglement or textile carding. These processes are performed at a temperature below the melting point of the binder filaments.
  • FIG. 1 is a schematic view of needle punch used for consolidating carbon fibers and non- woven fibers according to an aspect of the invention
  • FIG. 2 is a partial cross-sectional view of a needle punch board for consolidating carbon and non- woven fibers according to an aspect of the invention
  • FIG. 3 is an enlarged cross-sectional view of a portion of the needle punch board in FIG. 2 penetrating the carbon and non-woven fibers;
  • FIG. 4 is a plan view of randomly arranged carbon fiber filaments in the machine direction;
  • Figure 5 is a plan view of a first layer of randomly arranged carbon fiber filaments and a second layer of randomly arranged carbon fiber filaments positioned approximately 90 degrees to the first layer;
  • Figure 6 is a side view of a composite structure, including a layer of randomly arranged carbon fibers and a layer of pre-consolidated materials above and below the randomly arranged layer.
  • One aspect of the invention concerns a novel method for forming a hybrid composite including a carbon fiber layer or plurality of carbon fiber layers surrounded by at least a single carrying, or covering layer of fibers both above and below the carbon fiber layer(s).
  • the composite has improved structural properties, over the original batt or mat configuration, in the x, y and z - axes.
  • the electrical properties of the carbon fibers are preserved, and in some cases, improved.
  • the carrying of covering layer(s) can be non- woven fibers, such as, for example, polyester, polypropylene, polyethylene, nylon, or aramid staple fibers.
  • non-woven fibers such as, for example, polyester, polypropylene, polyethylene, nylon, or aramid staple fibers.
  • the carbon mat and the non-woven fibers are consolidated with a needle-punch technique.
  • the non-woven material can be in a staple fiber configuration that can either be carded, lap and batt condensed on the needle line or manufactured off-line and staged for the needle-punch hybridization.
  • the needles utilized are of a particular design in that they capture fibers from the carrying layers during the down stroke only.
  • the needles contain very small, non-aggressive barbs such that the barb is filled with the carrying layer staple fibers and merely displaces the carbon filaments during the penetration.
  • the staple fibers are partially pulled back through the material and ultimately released thus creating a "z" axis fiber orientation through the composite material thickness. Referring to FIG.
  • a carbon fiber web 10 is fed between a first or upper plate 12 and a second or lower plate 14, both of which are below a needle board 16. This area is referred to as the needle zone.
  • a first or top covering or carrying layer 18, and a second or lower covering or carrying layer 20 of non- woven fibers are fed to the needle zone above and below the carbon fiber 10.
  • the needle board 16 includes a plurality of needles 22 shown in greater detail in FIGS. 2 and 3.
  • the needles 22 include very small barbs 24, that fill with material from the top covering layer 18 as the needles 22 are moved downward through the covering and carbon fiber layers 18, 10, 20. This places fibers from the top covering layer 18 in the z-axis direction of the fabric and consolidates the layers.
  • the covering or carrying layers should have an areal weight in the 3 to 5 oz. square yard weight range.
  • the down stroke needle should be a type such as the Foster Needle 36HDB .
  • the frequency of needle penetrations should be between 450 and 1000 penetrations per square inch to provide the desired consolidation, density and thickness.
  • the result is a composite material that maintains the electrical properties of the carbon fibers and provides structural reinforcement in the x and z-axes. This type of needle- punch operation would be the preferred embodiment if structural and conductive performance characteristics are desired. Certain composite applications may require anisotropic properties where mechanical strength is required in the y-axis, or cross-machine direction.
  • the carbon fiber reinforced hybrid described above exhibits high mechanical strength in the machine direction with relatively low tensile properties in the cross-machine direction.
  • high strength, unidirectional products such as glass, carbon, or Kevlar
  • These products will also be consolidated and stabilized in the composite matrix by needling the covering and carrying layers as indicated previously. If a composite fiber architecture with high torsional stiffness is required, additional layers placed at a bias angle relative to the longitudinal directional can be added to the appropriate layers of 90° product.
  • various combinations of layers orientated at 0°, 90°, +45°, -45° can be incorporated by tacking or needle-punching to achieve the required mechanical and electrical properties.
  • Tacking is yet another-form of needle-punching wherein the number of needles used is greatly reduced resulting in a mechanically stable product. This product can then be handled without risk of displacing or disturbing the fiber orientation and incorporated into other hybrid products that will undergo the complete, needle-punch consolidation procedure.
  • the carbon mat and the non- woven fibers are consolidated with a stitching technique. With this technique, a plurality of smooth needles, threaded with a fiber or filament passes through the materials drawing a continuous filament through the thickness, effectively "sewing" the layers together.
  • This method can incorporate various materials in the stitching "threads" depending on the desired properties. Again, this method affords little or no damage to the carbon filaments and can be varied to provide a wide range of stitch penetrations and tensions to accommodate density and thickness. Structure can be added to the z-axis with this method by utilizing high strength stitching fibers and by varying the density and occurrence of the stitching fibers.
  • the carbon mat is employed as a high strength core material in a sandwich laminate. By adding high tensile strength materials to the carrying layers, both top and bottom, and maintaining a specific amount of loft and density in the carbon mat, a highly structural, lightweight product can be produced using both the needling and stitching methods.
  • the covering and carrying layers are laid together with woven, non- woven, knit, or braided fiber architectures by hand to create an optimum carbon mat hybrid.
  • a soluble binder or adhesive can be applied to the various components and vacuum pressure applied to consolidate.
  • the binder used on the fibers and fabrics should be compatible with any resin matrix selected for use with the composite in the ultimate, finished part.
  • the binders used could also be infused while under vacuum. If a heat activated binder is used, the carbon mat can be resistively heated to assist in the formation of the consolidated product (ox preform).
  • a resultant effect of this method is an improvement in electrical properties by virtue of the intimate contact formed between the random carbon filaments.
  • the fluid pressure on the carbon mat not only improves electrical conductivity but also improves mechanical performance characteristics by increasing the volumetric ratio of high strength carbon fibers.
  • the present invention also relates to a method for using batt, an arrangement of carbon. fibers, to produce a preform part that is used to form a finished part. More specifically, this invention relates to a novel method for applying pressure and heat to a random arrangement of carbon fibers consolidated with a binder to form a preform part. In addition to increasing the structural stability of the preform part, the disclosed method ensures electrical continuity and improved electrical conductivity in the preform part.
  • a preform part is an intermediate structure or object used in a subsequent process to form a finished part.
  • a preform part is used to form a reinforced plastic part.
  • the preform part has a structure that is very similar to the finished part. This structural attribute is referred to as a near-net shape.
  • the preforming process partially rigidifies the structure while leaving interstices between the fibers unfilled therefor permitting the use of a matrix resin to subsequently form a molded article.
  • Batt is an arrangement of carbon fibers, where the boundaries of the fibers roughly define a sheet-like shape.
  • a carbon fiber batt is characterized by a random arrangement of carbon fiber filaments in the machine or longitudinal direction as shown in FIG. 4. This means that filaments are positioned longitudinally but randomly arrayed throughout the sheet. As a result of the random arrangement in the machine direction, a carbon fiber batt is a high-loft product, meaning that the interstice or space between the intersection of the filaments is measurable.
  • Batt can be formed from either a single layer or multiple layers of randomly arranged carbon fiber filaments in the machine direction.
  • the subsequent layers can be applied over the first layer by the process equipment.
  • the subsequent layers can be positioned in line with the first layer or at various angles to the first layer, such as ⁇ 45 or ⁇ 90 degrees.
  • a method of forming a preform part comprises a number of steps.
  • the arrangement of carbon fibers is coated with a binder.
  • the binder stabilizes the carbon fibers in the arrangement.
  • binders allow the arrangement to remain pliable.
  • the binder can be in either in a liquid or dry form.
  • the binder must be chemically compatible with any resin that is used in the formation of the finished part.
  • the binder can be applied to the carbon fibers in a number of ways, including but not limited to spraying the binder onto the carbon fibers or submersing the arrangement in a vessel containing binder. To ensure that the binder stabilizes the carbon fibers, a sufficient quantity must be applied.
  • acceptable dry weight percentages range from 45% fiber and 55% binder to 98% fiber and 2% binder.
  • the binder is heat activated or set; however, binders that set at ambient temperatures are compatible with the methods disclosed herein.
  • a suitable binder is Altac® 363E, a dry powder binder that is manufactured by Reichhold Corporation.
  • Other suitable binders are Altac® 363EF, Pretx 100, Pretex 110, Pretex 120, Petex, 130, and Pretex 140, all of which are available from Reichhold Corporation.
  • the carbon fiber arrangement is placed on a forming surface.
  • the forming surface can be either a curved or planar surface.
  • the forming surface can be integrated into a conventional mold or remain a distinct structure.
  • Pressure is applied to the carbon fiber arrangement to shape or form the arrangement into a desired preform shape.
  • the desired preform shape is a near- net shape, or similar to the finished part shape.
  • the application of pressure improves the structural performance characteristics of the preform part.
  • Pressure can be applied in a number of ways, including but not limited to using a vacuum bag in connection with the forming surface.
  • a vacuum bag is a plastic membrane that is placed over the arrangement and the forming surface to define a cavity. A vacuum is drawn in the cavity thereby exerting pressure on the objects beneath the membrane.
  • the forming surface could be integrated into a lower portion of a mold.
  • a top portion of the mold can be positioned in close proximity to the lower portion such that the top portion exerts pressure on the carbon fiber arrangement to form the arrangement into the preform shape. Heat is then applied to the carbon fiber arrangement to set the binder.
  • the carbon fiber arrangement While heat is applied, the carbon fiber arrangement remains in the desired preform shape. Once the binder has set, the carbon fiber arrangement has solidified and become stable; however, the arrangement is still pliable. Unlike a cured resin, a set binder permits the arrangement to remain pliable. As a result of the solidification, the resulting preform part is no longer structurally unstable and difficult to handle.
  • Heat can be applied in a number of ways, including but not limited to applying an electric current to the carbon fibers to resistively heat the carbon fiber arrangement.
  • an electric current could be applied to a layer of conductive fibers in the forming surface to resistively heat the forming surface.
  • the arrangement and the forming surface could be resistively heated.
  • an electric current could be applied to a layer of conductive fibers in the upper and lower mold portions to resistively heat the forming surface.
  • an electric current could be applied directly to the carbon fiber arrangement.
  • other conventional methods could be used to heat the carbon fiber arrangement, including ovens, autoclaves, ultraviolet light, or ambient temperatures.
  • the resulting preform part is allowed to cool and is then removed from the forming surface.
  • the preform part is then ready to be used in forming a finished part.
  • the preform part can be infused or injected with curable resin and then subjected to a molding process where the resin is cured to produce a finished part.
  • a single layer or multiple layers of randomly arranged carbon fibers or batt are stacked with a single layer or multiple layers of pre-consolidated materials to form a composite structure.
  • a single layer of randomly arranged carbon fibers is surrounded by a layer of pre- consolidated material both above and below the randomly arranged carbon fiber layer as shown in Figure 6.
  • the boundaries of the arrangement layer are roughly defined by random arrangement and structure of the carbon fibers.
  • the composite structure has structural components in the x-axis, the y-axis, and the z-axis.
  • the pre-consolidated layers result from the combination of either woven or non- woven material layers. Unlike the carbon fiber arrangement layer, the material layers can be combined in a number of conventional mechanical ways, including needling, stitch-bonding, knitting, and braiding.
  • the arrangement of the pre-consolidated layers above and below "carries” and “covers” the carbon fiber arrangement layer and protects and stabilizes the carbon fibers during subsequent processing and handling.
  • the pre-consolidated material layer is positioned at an angle to the carbon fiber arrangement layer. Multiple pre-consolidated material layers can be stacked above and below the carbon fiber arrangement, each of which can be positioned at various angles to the carbon fiber arrangement. Preferably, the angle is approximately 90 degrees, but other angles between 0 and ⁇ 90 degrees will suffice.
  • the material layers can be polyester, polypropylene, polyethylene, nylon, aramid or carbon staple fibers.
  • the composite structure including the layer of randomly arranged carbon fibers and the layers of pre-consolidated materials, is coated with a binder.
  • the binder stabilizes the carbon fiber layer and the pre-consolidated layers.
  • the binder can be applied to the composite structure in a number of ways, including but not limited to spraying the binder onto the composite structure or submersing the composite structure in a vessel containing a binder dispersion.
  • the composite structure is placed on a forming surface.
  • the forming surface can be either a curved or planar surface.
  • the forming surface can be integrated into a conventional mold or remain a distinct structure.
  • Pressure is applied to the composite structure to shape or form the structure into a desired preform shape.
  • the desired preform shape is a near-net shape, or similar to the finished part shape.
  • the application of pressure improves the structural performance characteristics of the preform part.
  • Pressure can be applied in a number of ways, including but not limited to using a vacuum bag.
  • the forming surface could be integrated into a lower portion of a mold. A top portion of the mold can be positioned in close proximity to the lower portion such that the top portion exerts pressure on the composite structure to form the arrangement into the preform shape.
  • Heat is then applied to the composite to set the binder. While heat is applied, the composite structure remains in the desired preform shape. Once the binder has set, the composite structure has solidified and become stable; however, the structure is still pliable. Unlike a cured resin, a set binder permits the structure to remain pliable. As a result of the solidification, the resulting preform part is no longer structurally unstable and difficult to handle.
  • heat can be applied in a number of ways to set the binder the composite, including but not limited to applying an electric current to the carbon fibers to resistively heat the composite structure.
  • an electric current could be applied to a layer of conductive fibers in the forming surface to resistively heat the forming surface.
  • the structure and the forming surface could be resistively heated.
  • an electric current could be applied to a layer of conductive fibers in the upper and lower mold portions to resistively heat the forming surface.
  • an electric current could be applied directly to the carbon fibers in the structure.
  • other conventional methods could be used to heat the carbon fiber arrangement, including ovens, autoclaves, ultraviolet light, or ambient temperatures.
  • the resulting preform part is allowed to cool and is then removed from the forming surface.
  • the preform part is then ready to be used in forming a finished part.
  • a single layer or multiple layers of randomly arranged carbon fibers or batt are manually stacked with a single layer or multiple layers of pre-consolidated materials to form a composite structure.
  • a single layer of randomly arranged carbon fibers is surrounded by a layer of pre-consolidated material both above and below the randomly arranged carbon fiber layer.
  • Each of the pre-consolidated layers can be positioned at various angles to the carbon fiber arrangement. Preferably, the angle is approximately 90 degrees, but other angles between 0 and ⁇ 90 degrees will suffice.
  • the composite structure has structural components in the x-axis, the y-axis, and the z-axis.
  • the composited structure is placed on a forming surface.
  • the forming surface can be either a curved or planar surface.
  • the forming surface can be integrated into a conventional mold or remain a distinct structure.
  • Pressure is applied to the composite structure to shape or form the structure into a desired preform shape.
  • Pressure can be applied in a number of ways, including but not limited to using a vacuum bag.
  • the forming surface could be integrated into a lower portion of a mold.
  • a top portion of the mold can be positioned in close proximity to the lower portion such that the top portion exerts pressure on the composite structure to form the arrangement into the preform shape.
  • a binder is infused or injected into the composite structure while the structure remains under vacuum. The binder stabilizes the carbon fiber layer and the pre-consolidated layers.
  • the binder can be infused or injected in a number of ways, including but not limited to using an injection port.
  • Heat is then applied to the composite to- set the binder. While heat is applied, the composite structure remains in the desired preform shape. Once the binder has set, the composite structure has solidified and become stable; however, the structure is still pliable. As a result of the solidification, the resulting preform part is no longer unstable and difficult to handle.
  • the heat can be applied as previously set forth. Again, once a sufficient quantity of heat has been applied to set the binder, the resulting preform part is allowed to cool and is then removed from the forming surface. The preform part is then ready to be used in forming a finished part.

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Reinforced Plastic Materials (AREA)
  • Nonwoven Fabrics (AREA)
  • Laminated Bodies (AREA)

Abstract

La présente invention concerne un procédé de mise en forme d'un composite réunissant une couche en fibres de carbone entourée dessus et dessous d'au moins une couche de fibres de non-tissé. Les couches en fibres de carbone et en non-tissé sont agrégées selon un procédé unique de poinçonnage aux aiguilles. Selon un autre aspect de l'invention, les couches en fibres de carbone et les couches de fibres de non-tissé sont agrégées par couture. L'invention concerne également un procédé de mise en forme d'une pièce de paraison comprenant plusieurs opérations. En premier, on prend un assemblage de fibres de carbone que l'on enduit d'un liant qui est une colle liquide ou sèche. En deuxième, on place l'assemblage de fibres de carbone sur une surface de formage qui peut être incurvée ou généralement plate. En troisième, on exerce une pression sur l'assemblage de fibres de carbone au moyen d'une poche à vide ou de parties d'un moule conventionnel. On chauffe enfin l'assemblage de fibres de carbone de façon à faire prendre le liant. Ce chauffage peut se faire par application d'un courant électrique sur les fibres de carbone de façon à chauffer par effet joule l'assemblage de fibres de carbone. Une fois qu'on suffisamment chauffé pour assurer la prise du liant, on laisse refroidir la paraison obtenue puis on la dégage de la surface de formage. La paraison est alors prête à recevoir l'injection de résine et à être traitée au moule pour donner la pièce finie.
PCT/US2001/017983 2000-06-02 2001-06-01 Agregation de fibres de carbone a orientation aleatoire et mise en forme d'une paraison de fibres de carbone WO2001092002A2 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU2001284641A AU2001284641A1 (en) 2000-06-02 2001-06-01 Method for consolidation for random carbon fiber orientation and for forming a carbon fiber preform

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US20943500P 2000-06-02 2000-06-02
US60/209,435 2000-06-02
US21350900P 2000-06-22 2000-06-22
US60/213,509 2000-06-22

Publications (3)

Publication Number Publication Date
WO2001092002A2 true WO2001092002A2 (fr) 2001-12-06
WO2001092002A3 WO2001092002A3 (fr) 2002-12-27
WO2001092002A9 WO2001092002A9 (fr) 2004-05-21

Family

ID=26904168

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2001/017983 WO2001092002A2 (fr) 2000-06-02 2001-06-01 Agregation de fibres de carbone a orientation aleatoire et mise en forme d'une paraison de fibres de carbone

Country Status (2)

Country Link
AU (1) AU2001284641A1 (fr)
WO (1) WO2001092002A2 (fr)

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2003076499A1 (fr) * 2002-03-08 2003-09-18 Owens Corning Systeme de liant de mat de filaments continus
EP1560701A2 (fr) * 2002-11-01 2005-08-10 Bell Helicopter Textron Inc. Procede et appareil de renforcement dans le sens z de stratifies composites
WO2012059538A1 (fr) * 2010-11-03 2012-05-10 Sgl Carbon Se Tissu non tissé renforcé
EP2511080A1 (fr) 2011-04-12 2012-10-17 Fundacion Tecnalia Research & Innovation Dispositif pour la préparation de préformes de composants renforcés par fibre de carbone
US9409337B2 (en) 2013-11-08 2016-08-09 Georgia Tech Research Corporation Polyacrylonitrile/cellulose nano-structure fibers
WO2018102282A1 (fr) * 2016-11-30 2018-06-07 Continental Structural Plastics, Inc. Article thermoplastique de moulage à base de fibres hybrides et son procédé de fabrication
US10443617B2 (en) 2012-07-02 2019-10-15 United Technologies Corporation Functionally graded composite fan containment case
US10738168B2 (en) 2012-08-01 2020-08-11 Teijin Limited Random mat and fiber-reinforced composite material shaped product
CN111886130A (zh) * 2018-03-19 2020-11-03 福乐尼·乐姆宝公开有限公司 制作纤维预制件的方法以及由此获得的纤维预制件
CN113510946A (zh) * 2021-04-20 2021-10-19 济南大学 碳纤维复合材料模压机
CN114836898A (zh) * 2022-06-02 2022-08-02 江苏天鸟高新技术股份有限公司 一种针刺碳纤维网毡及其制备方法与应用
US11571861B2 (en) * 2019-10-25 2023-02-07 Spirit Aerosystems, Inc. System and method for thermoplastic welding using an induced thermal gradient
US11773514B2 (en) 2014-10-08 2023-10-03 Georgia Tech Research Corporation Method for making high strength and high modulus carbon fibers

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1488649A (en) * 1973-10-30 1977-10-12 Ici Ltd Needled fibrous structure
US4181513A (en) * 1974-11-05 1980-01-01 Toyobo Co., Ltd. Carbon adsorptive filter material with layers of reinforcing non woven fabrics needle punched
US4847140A (en) * 1985-04-08 1989-07-11 Helmic, Inc. Nonwoven fibrous insulation material
JPH01272854A (ja) * 1988-04-25 1989-10-31 Osaka Gas Co Ltd 炭素繊維製不織布の構造
JP2580265B2 (ja) * 1988-06-30 1997-02-12 大阪瓦斯株式会社 複合不織布

Cited By (22)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7083855B2 (en) 2002-03-08 2006-08-01 Owens Corning Fiberglass Technology, Inc. Continuous filament mat binder system
WO2003076499A1 (fr) * 2002-03-08 2003-09-18 Owens Corning Systeme de liant de mat de filaments continus
US8214981B2 (en) 2002-11-01 2012-07-10 Bell Helicopter Textron Inc. Method and apparatus for Z-direction reinforcement of composite laminates
EP1560701A4 (fr) * 2002-11-01 2006-11-22 Bell Helicopter Textron Inc Procede et appareil de renforcement dans le sens z de stratifies composites
US7993477B2 (en) 2002-11-01 2011-08-09 Bell Helicopter Textron Inc. Method and apparatus for Z-direction fiber insertion of discrete fibers for reinforcement of composite laminates
EP1560701A2 (fr) * 2002-11-01 2005-08-10 Bell Helicopter Textron Inc. Procede et appareil de renforcement dans le sens z de stratifies composites
WO2012059538A1 (fr) * 2010-11-03 2012-05-10 Sgl Carbon Se Tissu non tissé renforcé
CN103025940A (zh) * 2010-11-03 2013-04-03 西格里碳素欧洲公司 增强的无纺织物
EP2511080A1 (fr) 2011-04-12 2012-10-17 Fundacion Tecnalia Research & Innovation Dispositif pour la préparation de préformes de composants renforcés par fibre de carbone
US8764428B2 (en) 2011-04-12 2014-07-01 Fundacion Tecnalia Research & Innovation Device for the preparation of preforms of carbon fiber-reinforced components
US10443617B2 (en) 2012-07-02 2019-10-15 United Technologies Corporation Functionally graded composite fan containment case
US11168186B2 (en) 2012-08-01 2021-11-09 Teijin Limited Random mat and fiber-reinforced composite material shaped product
US10738168B2 (en) 2012-08-01 2020-08-11 Teijin Limited Random mat and fiber-reinforced composite material shaped product
US9409337B2 (en) 2013-11-08 2016-08-09 Georgia Tech Research Corporation Polyacrylonitrile/cellulose nano-structure fibers
US9771669B2 (en) 2013-11-08 2017-09-26 Georgia Tech Research Corporation Use, stabilization and carbonization of polyacrylonitrile/carbon composite fibers
US11773514B2 (en) 2014-10-08 2023-10-03 Georgia Tech Research Corporation Method for making high strength and high modulus carbon fibers
WO2018102282A1 (fr) * 2016-11-30 2018-06-07 Continental Structural Plastics, Inc. Article thermoplastique de moulage à base de fibres hybrides et son procédé de fabrication
US11987011B2 (en) 2016-11-30 2024-05-21 Teijin Automotive Technologies, Inc. Hybrid fiber based molding thermoplastic article and process of forming same
CN111886130A (zh) * 2018-03-19 2020-11-03 福乐尼·乐姆宝公开有限公司 制作纤维预制件的方法以及由此获得的纤维预制件
US11571861B2 (en) * 2019-10-25 2023-02-07 Spirit Aerosystems, Inc. System and method for thermoplastic welding using an induced thermal gradient
CN113510946A (zh) * 2021-04-20 2021-10-19 济南大学 碳纤维复合材料模压机
CN114836898A (zh) * 2022-06-02 2022-08-02 江苏天鸟高新技术股份有限公司 一种针刺碳纤维网毡及其制备方法与应用

Also Published As

Publication number Publication date
WO2001092002A9 (fr) 2004-05-21
WO2001092002A3 (fr) 2002-12-27
AU2001284641A1 (en) 2001-12-11

Similar Documents

Publication Publication Date Title
KR100218638B1 (ko) 부직포의 제조방법 및 이 방법으로 제조된 부직포
CA1175332A (fr) Article composite, et methode de fabrication connexe
US20200238659A1 (en) Planar composite material
US4410385A (en) Method of making a composite article
EP0361796B1 (fr) Procédé pour la fabrication d'une matière composite moulable
RU2583017C2 (ru) Содержащая однонаправленные волокнистые ленты волокнистая заготовка из пучков армирующих волокон и конструктивный элемент из композитного материала
JP5882240B2 (ja) ポリマー不織布を有する多軸積層体
KR101434077B1 (ko) 섬유 복합 재료의 편평한 반제품의 제조 방법
CN104853893B (zh) 制备半成品的方法和用于制备复合模塑件、尤其是纤维复合模塑件的半成品以及复合模塑件、尤其是纤维复合模塑件
JP2015232198A (ja) 縫合した多軸の布帛
US20150047780A1 (en) Stabilizable preform precursors and stabilized preforms for composite materials and processes for stabilizing and debulking preforms
JP2018080442A (ja) 平面状複合材料
WO2001092002A2 (fr) Agregation de fibres de carbone a orientation aleatoire et mise en forme d'une paraison de fibres de carbone
JP2018531307A (ja) 強化繊維製のテキスタイル基材
JP2018531307A6 (ja) 強化繊維製のテキスタイル基材
US4867086A (en) Method of making a dry fiber form and composites prepared therefrom
EP3843980A1 (fr) Produit et procédé
WO2013191073A1 (fr) Mat en fibre en carbone et matériau composite en fibre de carbone l'utilisant
JP5877431B2 (ja) 炭素繊維強化複合材料の製造方法
TWI781780B (zh) 熱塑性碳纖維複合材料結構及其製作方法
WO2020031771A1 (fr) Matériau de ruban de fibres renforcées et son procédé de production, corps moulé de résine renforcée de fibres et corps stratifié de fibres renforcées utilisant un matériau de ruban de fibres renforcées
JP4376118B2 (ja) 多軸織物、プリフォーム材、及び繊維強化プラスチック成形品
JP7623138B2 (ja) 少なくとも２つの０°の層を有する多軸製品
JP2023043395A (ja) 多軸繊維基材及びこれを用いた強化繊維樹脂成形体
CN117320862A (zh) 通过针织制造的预成型件、并入此类预成型件的复合材料产品和制造方法

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A2

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EE ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NO NZ PL PT RO RU SD SE SG SI SK SL TJ TM TR TT TZ UA UG US UZ VN YU ZA ZW

AL Designated countries for regional patents

Kind code of ref document: A2

Designated state(s): GH GM KE LS MW MZ SD SL SZ TZ UG ZW AM AZ BY KG KZ MD RU TJ TM AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE TR BF BJ CF CG CI CM GA GN GW ML MR NE SN TD TG

121 Ep: the epo has been informed by wipo that ep was designated in this application
DFPE Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed before 20040101)
AK Designated states

Kind code of ref document: A3

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EE ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NO NZ PL PT RO RU SD SE SG SI SK SL TJ TM TR TT TZ UA UG US UZ VN YU ZA ZW

AL Designated countries for regional patents

Kind code of ref document: A3

Designated state(s): GH GM KE LS MW MZ SD SL SZ TZ UG ZW AM AZ BY KG KZ MD RU TJ TM AT BE CH CY DE DK ES FI FR GB GR IE IT LU MC NL PT SE TR BF BJ CF CG CI CM GA GN GW ML MR NE SN TD TG

32PN Ep: public notification in the ep bulletin as address of the adressee cannot be established

Free format text: NOTING OF LOSS OF RIGHTS PURSUANT TO RULE 69(1)EPC

122 Ep: pct application non-entry in european phase
COP Corrected version of pamphlet

Free format text: PAGES 1/4-4/4, DRAWINGS, REPLACED BY NEW PAGES 1/3-3/3; DUE TO LATE TRANSMITTAL BY THE RECEIVING OFFICE

NENP Non-entry into the national phase

Ref country code: JP

点击 这是indexloc提供的php浏览器服务，不要输入任何密码和下载