• 专利附录
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    • 专利摘要:
    multiaxial non-pleated fabric, and preforms to produce composite components. the invention relates to a multiaxial fross fabric of at least two layers of multifilament reinforcement threads, which are arranged in parallel in the layers, next to each other, in order to be adjacent, the layers being arranged one on top of the other. the reinforcement threads of one layer and the neighboring layers are interconnected by sewing threads that extend in parallel with each other and are interspersed in a stitch width (w) and fixed in relation to the other, the sewing threads forming stitches of one stitch length (s) and the zero direction of the thick fabric being defined by the sewing threads. the layer reinforcement threads are arranged symmetrically to the zero direction of the thick fabric and form, with respect to the direction in which they extend, an angle (a) with respect to the zero direction, whose angle is not equal to 90º and not equal to 0º. the invention is characterized by the fact that the sewing threads have a linear density in the range of 10 to 35 dtex. the invention also relates to a preform produced from such multiaxial thick fabric.
    公开号:BR112012021917B1
    申请号:R112012021917-0
    申请日:2011-03-11
    公开日:2020-09-29
    发明作者:Ronny Wockatz
    申请人:Toho Tenax Europe Gmbh；
    IPC主号:
    专利说明:

    [001] The invention relates to a non-pleated fabric, made up of at least two overlapping layers of multifilament reinforcement threads, which are arranged within layers parallel to each other and confining in parallel, in which the reinforcement threads within a layer, as well as adjacent layers, are connected together and secured against each other by sewing threads proceeding in parallel with each other and separated from each other in a stitch width w, where the sewing threads form stitches with a length of point if the zero degree direction of the non-pleated fabric is defined by the sewing threads and where the reinforcement threads of the layers are symmetrically arranged with respect to the zero degree direction of the composite and, with respect to the direction of its extension, form an angle a with the zero degree direction.
    [002] Multiaxial non-pleated fabrics have been known in the market for a long time. Multiaxial non-pleated fabrics are understood to be structures made of a plurality of overlapping fiber layers, wherein the fiber layers comprise sheets of reinforcement threads arranged parallel to each other. The overlapping layers of fiber can be connected and secured together via a plurality of sewing or knitting threads arranged parallel to each other and running parallel to each other and forming stitches, so that multiaxial non-pleated fabric is stabilized in this way. The sewing or knitting threads thus form the zero degree direction of the multiaxial non-pleated fabric.
    [003] The fiber layers are superimposed, so that the reinforcing fibers of the layers are oriented parallel to each other or alternatively transversely. The angles are virtually infinitely adjustable. Usually, however, for multiaxial non-pleated fabrics angles of 0 °, 90 °, plus or minus 25 °, plus or minus 30 °, plus or minus 45 ° or plus or minus 60 ° are set and the structure is selected so that a symmetrical structure, with respect to the zero degree direction, results. Multiaxial non-pleated fabrics of this type can be produced, e.g. eg using standard warp knitting looms or stitch binding machines.
    [004] The composite fiber components produced using multiaxial non-pleated fabrics are suitable in a superb way to directly neutralize the forces introduced by the component's stress directions and thus ensure high toughness. The adaptation in multiaxial non-pleated fabrics, with respect to fiber densities and fiber angles, in the load directions present in the component, allows low specific weights.
    [005] Multiaxial non-pleated fabrics can be used, due to their structure, especially for the manufacture of complex structures. Multiaxial non-pleated fabrics are thus placed without matrix material in a mold, e.g. For example, for forming, they are adapted to the contours using increased temperatures. After cooling, a so-called, stable preform is obtained, within which the matrix material required to produce the composite component can subsequently be introduced via infusion or injection, or also by applying vacuum. Known methods in this case are the so-called liquid molding method (LM), or methods related to it, such as resin transfer molding (RTM), vacuum assisted resin transfer molding (VARTM), resin film infusion ( RFI), liquid resin infusion (LRI) or flexible resin infusion tooling (RIFT).
    [006] It is important on the one hand for the preform that the fibers within the layers, as well as the individual fiber layers, are attached to each other to a sufficient degree. On the other hand, with regard to the required three-dimensional conformation, a good draping of multiaxial non-pleated fabrics is necessary. Finally, it is also important that the multiaxial non-pleated fabric, shaped into the preform, can be easily penetrated by the matrix resin that is introduced via the methods listed above.
    [007] Multiaxial non-pleated fabrics and their manufacture are described, for example, in DE 102 52 671 Cl, DE 199 13 647 B4, DE 20 2004 007 601 Ul, EP 0 361 796 Al or US 6 890 476 B3. According to DE 10 2005 033 107 B3, initially individual mats, made of fibers or bundles of fibers unidirectionally arranged, are produced, in which said fibers or bundles of fibers are grasped at points by connecting lines and all connecting lines envelop and hold only one fiber or only one bundle of fibers. In a second step, a plurality of layers of mats produced in this way are superimposed at different angles to each other and connected to each other.
    [008] EP 1 352 118 A1 describes multiaxial non-pleated fabrics, whose layers of reinforcement fibers are retained together by means of fusible sewing threads. The use of fusible threads allows, according to one of the embodiments of EP 1 352 118 Al, a displacement of the layers together during the forming of multiaxial non-pleated fabrics above the melting temperature of the sewing threads and stabilization of the shape during the subsequent cooling down below the melting temperature, so that the stitches act as a means of connection in situ. The tension in the sewing threads results, according to the statements of EP 1 352 118 Al, initially in the formation of channel zones in the composite, resulting in a better infiltration of the matrix resin. Heating the composite structure above the melting temperature of the sewing threads then results in a reduction in tension for the sewing threads and as a result of a reduction in the waviness of the reinforcement fibers. The proportion of the sewing threads in the non-pleated fabric should, according to EP 1 352 118 A1, preferably be in the range of 0.5 - 10% by weight.
    [009] Sewing threads made of thermoplastic polymers, such as polyamide or polyester, are often used as described in EP 1 057 605 Bl, for example. According to information from US 6 890 476 Bl, the lines used there have a linear density of approximately 70 dtex. WO 98/10128 describes multiaxial non-pleated fabrics made of several overlapping layers, deposited at an angle of reinforcement fibers, said layers being sewn or knitted together via sewing threads. WO 98/10128 describes multiaxial non-pleated fabrics, where the stitch chains of the sewing threads have a caliber of 5 rows by 25.4 mm wide (= 1 inch) for example and a stitch width generally in the approximately 3.2 to approximately 6.4 mm (1/8 - 14 inch). The sewing threads used there have a linear density of at least approximately 80 dtex. In US 4 857 379 Bl also, yarns made for example from polyester were used to connect the reinforcement yarns by means of, e.g. eg, knitting or weaving processes, where the yarns used there have a linear density of 50 to 3300 dtex.
    [0010] DE 198 02 135 refers to multiaxial non-pleated fabrics for, p. ballistic applications, for which overlapping layers of warp and weft lines, arranged parallel to each other respectively, are connected to each other by joining threads. For multiaxial non-pleated fabrics shown in DE 198 02 135, the lines parallel to each other have a distance between them and the loops formed by the joining lines wrap around the warp or weft lines, respectively. For the joining lines used, linear densities in the range between 140 and 930 dtex are indicated. For multiaxial non-pleated fabrics described in WO 2005/028724 also, several layers of reinforcement threads with high linear density and arranged unidirectionally or parallel to each other, are connected by the union of lines that intertwine between said reinforcement threads and run around individual reinforcement wires. The reinforcement wires are separated from each other within the layers. As connecting lines, yarns, for example, made of poly vinyl alcohol, with a linear density of 75 denier or elastomeric yarns based on polyurethane with a linear density of 1120 denier, are used.
    [0011] Also, fiber mats placed at random or nonwoven, or cloths or mats of artificial fiber, are to some extent placed between layers made of reinforcing fibers in order to improve, e.g. e.g., the impregnability of fabrics or to improve, e.g. eg impact resistance. Multiaxial non-pleated fabrics having such mat-like intermediate layers are described, for example, in DE 35 35 272 C2, EP 0 323 571 Al, or US 2008/0289743 Al.
    [0012] The results show that today's multiaxial non-pleated fabrics can absolutely drape well and their impregnability with matrix resin can be satisfactory. A good level of characteristic values can be achieved for components that are produced using multiaxial non-pleated fabrics, with respect to flexural strength or tensile strength. However, these components often show an unsatisfactory level of characteristic values with respect to compression stresses and impact stresses.
    [0013] The disadvantages of unsatisfactory mechanical toughness under compression load and impact load have been sufficiently serious so far that, despite the better suitability mentioned above of materials, especially for complex components, the long-established technology called prepreg is employed and thus , greater time spent and higher production costs are accepted.
    [0014] Therefore, there is a need for multiaxial non-pleated fabrics, which result in improved component or material characteristics, in particular under compression and impact loading.
    [0015] It is therefore an objective of the present invention to provide a multiaxial non-pleated fabric, by means of which composite fiber components, having improved characteristics under compression or impact load, can be produced.
    [0016] The objective is achieved by a multiaxial non-pleated fabric, made up of at least two overlapping layers of multifilament reinforcement threads, which are arranged within layers parallel to each other and confined parallel, in which the reinforcement threads within a layer , as well as adjacent to the layers, are connected together and held together by sewing threads forming stitches proceeding parallel to each other and separated from each other in a stitch width w, in which the sewing threads form stitches with a stitch length s the zero degree direction of the non-pleated fabric is defined by the sewing threads, in which the reinforcement threads of the layers are symmetrically arranged with respect to the zero degree direction of the non-pleated fabric and, with respect to the direction of its extension, form an angle c with the direction of zero degree, said angle not equal to 90 ° or 0 ° and in which multiaxial non-pleated fabric is characterized by the fact that the sewing threads have a density l start in the range of 10 to 35 dtex.
    [0017] It has been shown that, in particular, the stability is significantly improved with respect to the compression load if the linear density of the sewing threads in the multiaxial non-pleated fabric falls within the required range according to the present invention. Fine sewing threads of this type have not been used in multiaxial non-pleated fabrics until now. Surprisingly, it has been shown that by using sewing threads in multiaxial non-pleated fabrics, which have the required linear density in accordance with the present invention, a significant increase in stability of the composites produced from them is achieved. This is attributed to the fact that the fiber structure of the individual fiber layers is significantly homogenized compared to known multiaxial non-pleated fabrics. In particular, it has been observed that the filaments of the reinforcement yarns show a straighter course than is the case for prior art non-pleated fabrics. The sewing threads preferably have a linear density in the range of 10 to 30 dtex and particularly preferably a linear density in the range of 15 to 25 dtex. The use of yarns, having a low linear density, at best as knitting lines for the production of, p. eg, knitting for textile applications, such as for the production of outerwear for outerwear, such as sports jackets, is known. Fuse airbags of this type are described, e.g. DE 93 06 255 Ul, in which, in the meantime, the knitting threads wrap around the warp and weft threads of the underlying fabric. This is also applicable to the fabric of WO 2006/055785 for motor vehicle containment systems (air bags), in which a layer of yarn in the warp direction and a layer of yarn in the weft direction are connected each other by means of knitting yarns having a low linear density.
    [0018] The individual layers constructed of multifilament reinforcement yarns of the non-pleated fabric according to the present invention can be produced by means of standard methods and apparatus and placed superimposed at defined angles with respect to the zero degree direction. Machines known in this field are LIBA machines or Karl Mayer machines. By this means, the reinforcement wires can also be positioned within the layers in relation to each other, so that they are confined, that is, they are adjacent essentially without gaps.
    [0019] However, it is also possible that the layers of the multiaxial non-pleated fabric according to the present invention comprise prefabricated unidirectional woven fabrics, produced from multifilament reinforcement yarns. For these unidirectional fabrics, the reinforcement threads, arranged parallel to each other and forming the respective layer, are connected to each other by chains produced from loose connecting lines, which extend essentially transversal to the reinforcement threads. Unidirectional fabrics of this type are described, for example, in EP 0 193 479 Bl or EP 0 672 776, to which explicit reference is made here with reference to this description.
    [0020] As reinforcement fibers or reinforcement threads, fibers or threads are considered to be commonly used in the field of fibrous composite technology. Preferably, the multifilament reinforcement yarns used in the multiaxial non-pleated fabric according to the present invention are carbon fiber, glass fiber or aramid yarns, or high-grade UHMW polyethylene yarns. Particularly preferable, these are carbon fiber yarns.
    [0021] The non-pleated fabrics according to the present invention are symmetrical with respect to their layer structure. This means that the number of layers, in multiaxial non-pleated fabrics, according to the present invention, in which the reinforcement threads form a positive angle a with the zero degree direction and the number of layers in which the reinforcement threads form a negative angle complementary to the zero degree direction, is the same. Thus, the multiaxial non-pleated fabric according to the present invention can, for example, have a structure with a layer of + 45 °, a -45 °, a + 45 ° and a -45 °. Usually, oc angles for multiaxial non-pleated fabrics are found in the range of ± 20 ° to approximately ± 80 °. Typical angles c are ± 25 °, ± 30 °, ± 45 ° and ± 60 °. In a preferred embodiment of the non-pleated fabric according to the present invention, the absolute value of the angle oc in the direction of degree zero is in the range of 15 ° to 75 °.
    [0022] In order to also accommodate, p. eg, more directions of tension in the last component, the multiaxial non-pleated fabric according to the present invention preferably also comprises layers of multifilament reinforcement threads in which the reinforcement threads form an angle of 0 ° with respect to the zero degree direction and / or layers in which the reinforcement wires form an angle of 90 ° with respect to the zero degree direction. These 0 ° and / or 90 ° layers are preferably located between the layers oriented at the oc angle. However, for example, a structure having the following directions is also possible: 90 °, + 30 °, -30 °, 0o, -30 °, + 30 °, 90 °, ie a structure in which the outer layers are formed 90 ° layers.
    [0023] Regarding the toughness related to the compression loads and / or impact loads of the composite components produced using the multi-axial non-pleated fabrics according to the present invention, it has been surprisingly determined that an especially good toughness level is achieved if the length of stitch s of the sewing threads is dependent on the width of stitch w and also the angle oc of the reinforcement threads of the multiaxial non-pleated fabric according to the present invention, satisfying the following relationships (I) and (II):
    where the multiplier B can assume values in the range of 0.9 <B <1.1 and n can assume values of 0.5, 1, 1.5, 2, 3 or 4, by means of which also for small values of w Itan oci 1/2/3 the stitch length s is in the required range according to equation (1). Stitch width w, that is, the distance between the sewing threads, is thus indicated in mm.
    [0024] The angle oc, is understood to be the angle in the direction of zero degree, when seen from above, in which the reinforcement threads of the first layer of multiaxial non-pleated fabric are arranged, reinforcement threads having an angle other than 90 ° and 0o to the zero degree direction. In the case where the reinforcement threads of the topmost layer or the topmost layers of multiaxial non-pleated fabric have an angle of 90 ° or 0o to the zero degree direction, then the first layer arranged under this layer or below these layers it is considered whose reinforcement wires have an angle differing from 90 ° and 0 °.
    [0025] In the examination of the fiber structure, that is, the course of the fibers or the filaments of the multifilament reinforcement threads of the layers of the multiaxial non-pleated fabric, it was found that, satisfying the relations (I) and (II), a very uniform course of fibers resulted, with a significantly reduced waviness of the threads and a significantly reduced appearance of spans between the bundles of thread. For this purpose it is obviously critical that, along the course of a bundle of yarn or fiber filament, the sewing threads pierce the fiber filament in different positions across the width of the fiber filament. For values usually established in relation to the stitch length and stitch width outside the ranges defined by the relations (I) and (II), it was observed that the penetration of the sewing threads along the extension of the reinforcement threads occurs essentially between them fibers or filaments or the same regions of the fiber filament or reinforcement yarn. This results, therefore, in a pronounced waviness in the course of the thread and in the formation of gaps between the filaments.
    [0026] Altogether, it was found that when using the sewing thread according to the present invention with low linear density and when satisfying the above-mentioned relationships (I) and (II) in the view above the layers of the threads reinforcement, the deflection caused by the penetration points of the sewing threads in the non-pleated fabric, also referred to as the curl angle, can be reduced by up to approximately 25%. At the same time, the resulting waviness areas, that is, the areas or regions where the filaments or lines show a deflection, can be reduced by approximately 40% and the free spaces between fibers, resulting in regions with an increased proportion of resin and reduced toughness in the component, are thus significantly reduced.
    [0027] At the same time, by reference to micrographs of composite laminates based on multiaxial non-pleated fabrics according to the present invention, it was found that, using the preferred sewing threads according to the present invention with low linear density, surprisingly, a significant homogenization of the course of the reinforcement lines was achieved in the direction of observation parallel to the extension of the layers of the reinforcement wires and perpendicular to the reinforcement wires. Thus, using a sewing thread with a linear density of 23 dtex, an essentially linear course of the filaments of the reinforcement threads was achieved. Using a sewing thread with a linear density outside the required range according to the invention, already at a linear density of 48 dtex, when seen through the mentioned cross section of the composite laminate, all filaments showed a wave-shaped course very irregular, with amplitudes of variation in the order of the thickness of a layer of reinforcement threads.
    [0028] Here, the stitch length can be in the range of 2 mm to 4 mm. At stitch lengths above 4 mm, sufficient stability of the multiaxial non-pleated fabric according to the present invention can no longer be guaranteed. In contrast, below 2 mm, an excessively high number of imperfections appears in the non-pleated fabric. In addition, the economy of production of multiaxial non-pleated fabrics is greatly reduced.
    [0029] The yarns usually used to produce non-pleated yarn fabrics can be considered for use as sewing threads, as long as they have the required linear density according to the invention. Preferably the sewing threads are multifilament threads. Preferably, the sewing threads consist of polyamide, polyamide, polyester, polyacrylic, polyhydroxy ether, or copolymers of these polymers. The sewing threads consist of particularly preferable multifilament yarns made of polyester, polyamide or polyhydroxy ether, or copolymers of these polymers. In the process, sewing threads can be used which, during the last resin injection, e.g. melted above the resin injection temperature, but below the curing temperature of the resin used. The wires can also melt at the curing temperature. The sewing threads can also be of the type that can dissolve in the matrix resin, e.g. during injection or during curing of the resin. Sewing threads of this type are described, e.g. e.g., in DE 199 25 588, EP 1 057 605 or US 6 890 476, which explicit reference is made with reference to this description.
    [0030] It is advantageous if the sewing threads have an elongation at break of> 50% at room temperature. Due to the high elongation at break, a better draping of the multiaxial non-pleated fabric according to the present invention is achieved, by means of which more complex structures or components can be realized. Within the context of the present invention, the sewing threads are also understood as threads that are not incorporated via sewing into the multiaxial non-pleated fabric according to the present invention, however, instead, via other textile stitch or loop formation processes , such as in particular via knitting processes. The stitches, via which the sewing threads connect the layers of multiaxial non-pleated fabric to each other, can have the types of weaves that are usual for multiaxial non-pleated fabrics, such as knitting or edge weave. An edge weave is preferred.
    [0031] In a preferred embodiment of the multiaxial non-pleated fabric according to the present invention, a non-woven fabric is arranged on top of and / or between at least two layers of reinforcement yarns, i.e., the yarn layers reinforcement, and said nonwoven is connected to the layers of reinforcement threads by the sewing threads. A textile cloth made from non-directional short cut fibers or artificial fibers can be used for the nonwoven, or a layer placed at random, made of continuous filaments, this layer should be bonded, e.g. eg, through the application of temperature and through pressure, whereby the filaments melt at the points of contact and thus form the nonwoven. An advantage of using a nonwoven between the reinforcement layers lies, among other things, in a better draping and / or a better ability of the multiaxial non-pleated fabric to be infiltrated with the matrix resin. For this process, the nonwoven may, for example, be a glass nonwoven or a nonwoven made of carbon fibers.
    [0032] Preferably, the nonwoven is made of a thermoplastic polymeric material. Nonwovens of this type are, as already explained, described, for example, in DE 35 35 272 C2, EP 0 323 571 Al, US 2007/0202762 Al or US 2008/0289743 Al. With respect to an appropriate selection of materials Thermoplastic polymeric, non-woven can act as an agent to increase impact resistance, and additional means to increase impact resistance then no longer need to be added to the matrix material itself. The nonwoven must still have sufficient stability during the infiltration of the multiaxial non-pleated fabric with matrix material, however it must fuse at subsequent pressing and / or curing temperatures. Preferably, therefore, the thermoplastic polymeric material forming the nonwoven has a melting temperature in the range of 80 to 250 ° C. For applications where epoxy resins are introduced as matrix materials, nonwovens made of polyamide have been proven.
    [0033] In this way it is advantageous if the nonwoven comprises two thermoplastic polymeric components that have different melting temperatures, that is, a first polymeric component with a lower melting temperature and a second polymeric component with a higher melting temperature. In this way, the nonwoven can consist of a mixture of monocomponent fibers, with different melting temperatures, thus being a hybrid nonwoven. However, the nonwoven may also consist of bicomponent fibers, for example, core-wrap fibers, whereby the fiber core is made of a higher melting polymer and the wrap is made of a lower polymer Fusion.
    [0034] During the processing of multiaxial non-pleated fabrics according to the present invention with hybrid or non-woven bicomponent fabrics of this type in preforms, that is, during the molding of multiaxial non-pleated fabrics with an adequate application of heat during molding at temperatures above the melting point of the lowest melting nonwoven component, but below the melting point of the highest melting nonwoven component, good conformability can be achieved and, after cooling, good stabilization and fixation of the conformed non-pleated fabric. Similar to a nonwoven made of bicomponent fibers, the nonwoven can also be made, e.g. e.g., a randomly placed layer of fibers made from the second polymeric component, wherein the first polymeric component is applied to the fibers of the second polymeric component, e.g. by spraying or coating. The coating can, for example, result from impregnation with a dispersion or solution of the first polymeric component, in which, after impregnation, the liquid part of the dispersion, or the solvent, is removed. It is also possible that a nonwoven, constructed of fibers made from the second polymeric component, contains the first polymeric component in the form of fine particles embedded between the fibers of the second polymeric component.
    [0035] In a preferred embodiment of the multiaxial non-pleated fabric according to the present invention, the first polymeric component, with a higher melting temperature, forming the nonwoven, has a melting temperature in the range between 140 ° and 250 ° C. It is also preferred that the second polymer component, with a lower melting temperature, has a melting temperature in the range between 80 and 135 ° C.
    [0036] In another preferred embodiment, the nonwoven is made of a polymeric material that is at least partially soluble in the matrix material. Particularly preferred is that the polymeric material is soluble in epoxy resins, cyanate ester resins or benzoxazine resins. Nonwovens of these types are described, for example, in US 2006/0252334 or EP 1 705 269. Most particularly preferred is a nonwoven made of polyhydroxy ether because it dissolves in the matrix resin and cross-links with the matrix resin during its process cure, to form a homogeneous matrix.
    [0037] In an equally preferred embodiment, the nonwoven is constructed of a first thermoplastic polymer component with a higher melting temperature and a second thermoplastic polymer component with a lower melting temperature, and the second polymer component is at least less partially soluble in the matrix material. Particularly preferable, the second, lower melting polymer component is soluble in epoxy resins. Preferably, this nonwoven is a hybrid nonwoven, i.e., a nonwoven made of a mixture of monocomponent fibers with different melting temperatures. Preferably, therefore, the first polymer component with a higher melting temperature has a melting temperature in the range between 140 and 250 ° C. At such temperatures, the part of the nonwoven that consists of the first polymeric component melts only above the temperatures that, as a rule, prevail during the injection of the matrix resin. Because the first polymeric component does not yet melt at the resin injection temperature, a good dimensional consistency of the multiaxial non-pleated fabric is guaranteed at this stage.
    [0038] Particularly preferable, the first polymeric component is made of a polyamide homopolymer or a polyamide copolymer or a mixture of polyamide homopolymers and / or polyamide copolymers. In particular, the polyamide homopolymer or polyamide copolymer is a polyamide 6, polyamide 6.6, polyamide 6.12, polyamide 4.6, polyamide 11, polyamide 12 or a copolymer based on polyamide 6/12.
    [0039] It is also preferred that the second polymeric component of this nonwoven has a melting temperature in the range between 80 and 135 ° C. At the same time, however, as explained, it must be soluble in the matrix material. Therefore, the second polymeric component is particularly preferable a polyhydroxy ether that completely dissolves in the resin system, especially in epoxy resins, cyanate ester resins or benzoxazine resins already during the infiltration of multiaxial non-pleated fabric according to the present invention with these matrix resins, that is, for example, during the resin infusion process, and then form the matrix resin system together with the matrix resin. In contrast, the first polymeric component does not dissolve in the matrix system and remains during and after the infusion process and also after the matrix system has cured, comprising its own phase.
    [0040] Thus, with regard to the characteristics of the composite components produced using the multi-axial non-pleated fabrics according to the present invention, especially with regard to their impact resistance and their matrix content, it is advantageous if the non-woven contains the first polymeric component in a proportion of 20 to 40% by weight and the second polymeric component in a proportion of 60 to 80% by weight. Altogether, it is preferable if the nonwoven present in the multiaxial non-pleated fabric according to the present invention has a mass per unit area in the range of 5 to 25 g / m2 and, particularly preferable, a mass per unit area in the range from 6 to 20 g / m2.
    [0041] Multiaxial non-pleated fabrics according to the present invention are distinguished by good draping and good resin permeability. In addition, they enable the production of components with high stability against compression load and high tolerance to impact load. They are, therefore, especially suitable for the production of so-called preforms, from which more complex fiber composite components are produced. Therefore, the present invention also relates especially to preforms for the production of composite fiber components, which contain the multiaxial non-pleated fabrics according to the present invention.
    [0042] The invention will be explained in more detail on the basis of the following figures and examples, in which the scope of the invention is not limited by the examples.
    [0043] Figure 1 shows a photo of a segment of a sewed multiaxial non-pleated fabric, seen from above in an enlarged presentation.
    [0044] Figure 2 shows a schematic representation of the segment of a sewed multiaxial non-pleated fabric, shown in Figure 1, seen from above (negative presentation).
    [0045] Figure 1 and Figure 2 show a photo of a segment of a multiaxial non-pleated fabric seen from above, in which the uppermost layer of the non-pleated fabric is visible. In this way, Figure 2 presents the segment shown in Figure 1 as a negative for better representation, that is, areas that appear white in Figure 1, appear black in Figure 2 and black areas in Figure 1 appear white in Figure 2. topmost layer can be recognized by running in the figures, from left to right, carbon fiber filament yarns 1 from left to right, arranged in parallel with each other and adjoining, yarns 1 being connected by sewing threads 2 between themselves and the layer lying beneath them, which cannot be seen in the figures. The multiaxial non-pleated fabric segment, shown in Figures 1 and 2, is rotated 45 ° in the plane, so that the sewing lines do not run in the 0o direction, but certainly at a 45 ° angle. This means that the carbon fiber threads, arranged at a 45 ° angle to the sewing threads, run from left to right in Figures 1 and 2. Due to the formation of stitches (fringe weave), the threads seam 2 penetrates the carbon fiber filament yarns 1 at a defined distance, which corresponds to stitch length s, where seam lines 2 have a distance w from each other, designated as the stitch width.
    [0046] As a result of the penetration of the sewing threads 2 through the respective layer of multiaxial non-pleated fabric, gaps 3 appear between the filaments of the carbon fiber threads 1 and fiber deflections occur, of which an opening angle δ can be determined. Due to the fiber deflections between the filaments of the carbon fiber yarns, open spaces arise between the filaments, whose two-dimensional extension in the observation plane within the context of the present invention is designated as the wave area A. In these open spaces there will be in the subsequent component an increased proportion of resin and a decreased toughness of the component. Examples 1 and 2
    [0047] A multiaxial non-pleated fabric, based on carbon fibers, was produced in a multiaxial system (type "Cut & Lay" Carbon, Karl Mayer Textilmaschinenfabrik GmbH). For this purpose, initially individual layers with a mass per unit area of 134 g / m2 were produced from carbon fiber yarns (Tenax®-E IMS65 E23 24k 830tex; Toho Tenax Europe GmbH) placed parallel to each other and in contact each other. Two of these individual layers were superimposed, so that the lower layer in relation to the production direction of the multiaxial non-pleated fabric had an oc angle of + 45 ° and the upper layer had an oc angle of -45 °. The overlapping individual layers were knitted together using sewing threads in a fringe weave. The sewing threads used in Example 1 consisted of a copolyamide and had a linear density of 23 dtex. In Example 2, the sewing threads were used made of polyester with a linear density of 35 dtex. Stitch length s was 2.6 mm and stitch width w was 5 mm.
    [0048] To evaluate the quality of the non-pleated fabric, produced in this way, photos of the surface of the non-pleated fabric were produced using a calibrated reflected light scanner, with a resolution of 720 dpi and evaluated by means of optical image evaluation using Software Analysis Auto5 (Olympus). The evaluation was carried out with respect to fiber deflections caused by the penetration of the sewing threads, characterized by the opening angle δ, and with respect to the resulting A-wave areas, corresponding to the schematic presentation shown in Figure 2. The results obtained are listed in Table 1. Comparative Examples 1 and 2
    [0049] The procedure of Example 1 was repeated. In Comparative Example 1, however, polyester sewing threads with a linear density of 48 dtex were used and in Comparison Example 2 polyester sewing threads with a linear density of 75 dtex were used. The results with respect to fiber deflections, caused by the penetration of the sewing threads, characterized by the opening angle δ, and with respect to the resulting A-wave areas are also specified in Table 1. Table 1
    Examples 3 and 4
    [0050] In order to determine the influence of different linear densities of sewing thread on the mechanical characteristics of a laminate, non-pleated fabrics (type 1) were produced as in Example 1, made of two individual layers, oriented at + 45 ° and -45 °, made of carbon fiber yarns (Tenax®-E IMS65 E23 24k 830tex; Toho Tenax Europe GmbH), placed parallel to each other and confining each other, the layers having a mass per unit area of 134 g / m2. Likewise, non-pleated fabrics were produced, whose individual layers were oriented at - 45 ° and + 45 ° (type 1). The individual layers of type 1 and type 2 non-pleated fabrics were sewn (knitted) together using sewing threads with a linear density of 23 dtex (Example 3) or 35 dtex (Example 4), as indicated in Example 1 .
    [0051] A layer of a non-pleated fabric with + 457- 45 ° orientation (type 1) was combined with a layer of a non-pleated fabric symmetrical to it with -457 + 45 ° (type 2) overlapping in a stack of four individual layers to produce a laminate. This process was repeated and in this way a stack of a total of eight of these four overlapping individual layers was constructed so that the entire stack comprised a total of 32 layers. Through this procedure, a pile was produced whose layers were knitted together using 23 dtex sewing threads (Example 3) and a pile whose layers were knitted together using 35 dtex sewing threads (Example 4) .
    [0052] The cells thus produced were further processed via a method of infusing resin into laminates. Hexcel's HexFlow RTM6 epoxy system, which cures at 180 ° C, was used as the resin system. A laminate was produced with a total thickness after infusion and curing of 4.0 mm and a fiber volume content of 60% vol.
    [0053] The laminate was rotated by 45 ° C, so that the carbon fibers were oriented at 0 ° and 90 °. Test specimens according to DIN EN 6036-11 were produced from the laminate thus presented, the edges of said test specimens extending towards the carbon fibers of the laminate, that is, the orientation of the fiber in the test specimens was 9070 °. The compressive strength for the test specimen thus produced was determined using a test machine, Zwick Z 250, according to DIN EN 6036. The results are summarized in Table 2.
    [0054] In addition, micrographs of cross sections perpendicular to the extension of the surface of the individual layers and parallel to the 0 ° orientation of the carbon fibers were produced for the laminates. The micrographs are summarized in Table 3. It shows that when using 23 dtex and 35 dtex sewing threads there was a good straightness of the carbon fibers in the 0o orientation (recognizable in the micrographs as light colored lines), that is , the carbon fibers do not show or show only a small deviation from the straight line. Comparative Example 3
    [0055] The procedure of Example 3 was repeated. However, to produce non-pleated fabrics having -457-45 ° orientation (type 1) and non-pleated fabrics symmetrical to them having -457 + 45 ° orientation (type 2), the sewing lines with a linear density of 45 dtex were used in Comparative Example 3. The results are listed in Table 2. Table 2:

    [0056] For the laminate of Comparative Example 3, a micrograph of a cross section perpendicular to the surface extension of the individual layers and parallel to the 0 ° orientation of the carbon fibers was also produced. The micrograph of Comparative Example 3 is also found in Table 3. The use of sewing threads with 48 dtex for the laminate of Comparative Example 3 resulted in a comparatively turbulent image: the carbon fibers in the 0 ° orientation (recognizable in the micrograph as lines light colored) show a distinct wavy course, that is, partly clear deviations from a straight line course. Due to the thicker seam lines, the carbon fibers ripple perpendicular to the length of the individual layers. Deviations of this type from a straight line course of carbon fibers could be the cause of decreased compressive strength. Examples 5 to 7
    [0057] The procedures of Example 1 and Example 3 were repeated, where sewing threads with a linear density of 23 dtex were used. While maintaining a 5 mm stitch width w, the stitch length was varied and the stitch lengths were set at 3.3 mm (Example 5), 2.5 mm (Example 6) and 2.2 mm ( Example 7). Tablea 3:

    [0058] It was found that the values obtained for compressive strength are at a high total level due to the use of low linear density sewing threads, with a linear density of 23 dtex. However, the laminate of Example 6, for which a stitch width for the production of non-pleated fabrics was set at 2.5 mm, had the lowest compressive strength. Here it is observed that the 5 mm stitch width corresponds exactly to the doubling of the 2.5 mm stitch length and thus the stitch width is an integer multiple of the stitch length. This results in the fact that, in an orientation of the carbon fibers at an angle of + 45 ° or -45 °, there is a high risk that the penetration of the sewing threads in the same carbon fiber thread occurs along its length in the same place over its width. As a result, a split of the carbon fiber yarn can occur along its entire length, which results in a reduction of the distribution of forces under compression stress in the direction of the fiber orientation. Table 4:
    权利要求:
    Claims (12)
    [0001]
    1. Multiaxial non-pleated fabric made up of at least two overlapping layers of reinforcement threads (1) multifilament, which are arranged within layers parallel to each other, confining in parallel, where the reinforcement threads (1) within a layer , as well as in the adjacent layers, are connected to each other and held together by sewing threads (2) forming stitches proceeding parallel to each other and separated by a stitch width w, in which the sewing threads (2) form stitches with a stitch length s, and the zero-degree direction of the non-pleated fabric is defined by the sewing threads (2), and where the reinforcement threads (1) of the layers are symmetrically arranged with respect to the zero-degree direction of the non-fabric pleated and, with respect to the direction of its extension, form an angle oc with the direction of degree zero, said angle not being equal to 90 ° or 0o, and in which the sewing lines (2) have a linear density in the range of 10 to 35 dtex, the non-pleated fabric being characterized by the fact that the stitch length s of the sewing threads (2) depends on the stitch width w, as well as the oci angle of the reinforcement threads (1), and satisfies the relationships (I) and (II): 2 mm <s <4 mm (I) and,
    [0002]
    2. Multiaxial non-pleated fabric according to claim 1, characterized by the fact that the absolute value of the angle oc in relation to the zero degree direction is in the range of 15 ° and 75 °.
    [0003]
    3. Multiaxial non-pleated fabric according to claim 1 or 2, characterized in that the non-pleated fabric further comprises layers of reinforcement threads (1) multifilament, in which the reinforcement threads (1) form an angle of 0 ° with respect to to the zero degree direction and / or layers in which the reinforcement wires (1) form an angle of 90 ° with respect to the zero degree direction.
    [0004]
    4. Multiaxial non-pleated fabric according to any one of claims 1 to 3, characterized in that the sewing threads (2) have an elongation at break of> 50% at room temperature.
    [0005]
    Multiaxial non-pleated fabric according to any one of claims 1 to 4, characterized in that the sewing threads (2) have a linear density in the range of 10 to 30 dtex.
    [0006]
    Multiaxial non-pleated fabric according to any one of claims 1 to 5, characterized in that the sewing threads (2) are multifilament threads made of polyester, polyamide or polyhydroxy ether, or copolymers of these polymers.
    [0007]
    7. Multiaxial non-pleated fabric according to any one of claims 1 to 6, characterized in that the multifilament reinforcement yarns (1) are made of carbon fiber, glass fiber or aramid yarns, or high-grade UHMW polyethylene yarns .
    [0008]
    Multiaxial non-pleated fabric according to any one of claims 1 to 7, characterized in that a non-woven fabric is arranged and / or between at least two layers.
    [0009]
    9. Multiaxial non-pleated fabric according to claim 8, characterized by the fact that the non-woven fabric has a mass per unit area in the range of 5 to 25 g / m2.
    [0010]
    10. Multiaxial non-pleated fabric according to claim 8 or 9, characterized in that the non-woven fabric comprises thermoplastic polymer components with different melting temperatures.
    [0011]
    11. Multiaxial non-pleated fabric according to claim 10, characterized in that the polymer component with the lowest melting temperature has a melting temperature in the range between 80 ° and 135 ° C.
    [0012]
    Multiaxial non-pleated fabric according to claim 10 or 11, characterized in that the polymer component with the highest melting temperature has a melting temperature in the range between 140 ° and 250 ° C.
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    同族专利:
    公开号 | 公开日
    CA3024262A1|2011-09-22|
    CA2793096C|2019-01-15|
    KR20130018774A|2013-02-25|
    SI2547816T1|2017-01-31|
    CN104553109A|2015-04-29|
    CN102803592A|2012-11-28|
    TWI529273B|2016-04-11|
    US8613257B2|2013-12-24|
    PL2547816T3|2017-01-31|
    JP2015232198A|2015-12-24|
    US20120318182A1|2012-12-20|
    RU2555688C2|2015-07-10|
    EP2547816B1|2016-07-27|
    AU2014227431B2|2015-08-13|
    RU2012144341A|2014-04-27|
    PT2547816T|2016-10-26|
    ES2599402T3|2017-02-01|
    HUE029142T2|2017-02-28|
    CN102803592B|2015-01-21|
    AU2011229315A1|2012-09-06|
    KR101858429B1|2018-05-17|
    EP2547816A1|2013-01-23|
    EP3103906B1|2022-01-19|
    JP5792206B2|2015-10-07|
    AU2014227431A1|2014-10-02|
    EP3103906A1|2016-12-14|
    CA2793096A1|2011-09-22|
    TW201139773A|2011-11-16|
    BR112012021917A2|2016-05-31|
    DK2547816T3|2016-11-14|
    AR080772A1|2012-05-09|
    CA3024262C|2020-01-07|
    JP2013522486A|2013-06-13|
    WO2011113751A1|2011-09-22|
    AU2011229315B2|2014-09-11|
    CN104553109B|2017-04-12|
    AU2011229315C1|2015-01-22|
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    法律状态:
    2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-02-19| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|
    2020-01-14| B06A| Patent application procedure suspended [chapter 6.1 patent gazette]|
    2020-07-07| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-09-29| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 11/03/2011, OBSERVADAS AS CONDICOES LEGAIS. |
    2020-12-29| B25D| Requested change of name of applicant approved|Owner name: TEIJIN CARBON EUROPE GMBH (DE) |
    优先权:
    申请号 | 申请日 | 专利标题
    EP10002869|2010-03-18|
    EP10002869.5|2010-03-18|
    PCT/EP2011/053657|WO2011113751A1|2010-03-18|2011-03-11|Stitched multiaxial scrims|
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