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    • 专利摘要:
    The invention relates to a method of manufacturing a preimpregnated fibrous material comprising a fibrous material of continuous fibers and a thermoplastic polymer matrix, characterized in that said preimpregnated fibrous material is made of a single unidirectional ribbon or a plurality of ribbons unidirectional parallels and in that said method comprises the following steps: i) impregnating said fibrous material in the form of a wick or several parallel locks, by said thermoplastic polymer in the form of a powder in a fluidized bed (22); ii) shaping said wick or said parallel locks of said fibrous material impregnated according to step i), by calendering by means of at least one heating radiator (51, 52, 53) in the form of a single unidirectional ribbon or of a plurality of unidirectional parallel ribbons with, in the latter case, said heating calender comprising a plura a plurality of calendering grooves (73), preferably up to 200 calendering grooves, in accordance with the number of said tapes and with a pressure and / or spacing between the rolls of said calender controlled by a slave system.
    公开号:FR3017329A1
    申请号:FR1451137
    申请日:2014-02-13
    公开日:2015-08-14
    发明作者:Patrice Gaillard；Gilles Hochstetter；Thibaut Savart
    申请人:Arkema France SA；
    IPC主号:
    专利说明:

    [0001] FIELD OF THE INVENTION [0001] The present invention relates to a method of manufacturing a fibrous material pre-impregnated with thermoplastic polymer.  More particularly, the invention relates to a method of manufacturing a preimpregnated fibrous material comprising an impregnation step followed by a shaping step for obtaining ribbons of fibrous material pre- impregnated, of calibrated dimensions, directly usable for the manufacture of three-dimensional composite parts.  In the present description, the term "fibrous material" means an assembly of reinforcing fibers.  Before it is shaped, it is in the form of wicks.  After shaping, it comes in the form of strips, or tablecloths, or pieces.  When the reinforcing fibers are continuous, their assembly constitutes a fabric.  When the fibers are short, their assembly constitutes a felt or a nonwoven.  The fibers that can be used in the composition of the fibrous material are more particularly carbon fibers, glass fibers, basalt fibers, silicon carbide fibers, polymer-based fibers, vegetable fibers, or cellulosic fibers used alone or as a mixture.  Such preimpregnated fibrous materials are particularly intended for the production of lightweight composite materials for the manufacture of mechanical parts having a three-dimensional structure and having properties of good mechanical strength, thermal and capable of discharging electrostatic charges. , that is to say properties compatible with the manufacture of parts in particular in the fields of mechanics, aeronautics and nautical, automotive, energy, health and medical, army and armaments, sports and recreation, and electronics.  Such preimpregnated fibrous materials are also called composite materials.  They comprise the fibrous material, constituted by the reinforcing fibers, and a matrix constituted by the impregnating polymer.  The primary role of this matrix is to maintain the reinforcing fibers in a compact form and to give the desired shape to the final product.  Such a matrix is used inter alia to protect the reinforcing fibers against abrasion and an aggressive environment, to control the surface appearance and to disperse any fillers between the fibers.  The role of this matrix is important for the long-term behavior of the composite material, particularly with regard to fatigue and creep.  PRIOR ART] [0007] Good quality of the three-dimensional composite parts manufactured from preimpregnated fibrous materials therefore passes through a control on the one hand of the process for impregnating the reinforcing fibers with the thermoplastic polymer and on the other hand of the shaping process of the preimpregnated fibrous material in the form of a semi-finished product.  In this description, the term "band" is used to designate strips of fibrous material whose width is greater than or equal to 100mm.  The term "ribbon" is used to designate ribbons of calibrated width and less than or equal to 100 mm.  Until now, the manufacture of fibrous material webs reinforced by impregnation of thermoplastic polymer or thermosetting polymer was carried out according to several processes which depend in particular on the nature of the polymer, the type of final composite material desired and its field of applications.  Powder deposition or molten polymer extrusion technologies are used to impregnate the reinforcing fibers with thermosetting polymers, such as epoxy resins for example, as described in WO2012 / 066241A2.  These technologies are not generally applicable directly to the impregnation with thermoplastic polymers, in particular those with a high melting temperature, which have a melt viscosity that is too high to obtain satisfactory impregnation of the fibers and semi-finished products or finished of good quality.  Another known method of impregnation is the continuous passage of the fibers in an aqueous dispersion of polymer powder or aqueous dispersion of polymer particles or emulsion or aqueous polymer suspension.  For example, reference can be made to EP0324680.  In this process, a dispersion of micron-sized powders (about 20 μm) is used.  After soaking in the aqueous solution, the fibers are impregnated with the polymeric powder.  The process then involves a drying step of passing the impregnated Ref: 0390-ARK43 fibers into a first oven to evaporate the absorbed water during soaking.  A heat treatment step of passing the impregnated and dried fibers into a second heating zone at high temperature is then required to melt the polymer to adhere, disperse and coat the fibers.  The main disadvantage of this method is the homogeneity of the deposit which is often imperfect.  Another problem related to this process is the high porosity induced by the poor distribution of the polymer within the fibers, which can persist after the heat treatment step, thus causing the appearance of a large number of defects in the material. fibrous prepreg.  The preimpregnated fibrous material then needs to be shaped in the form of ribbons for example.  The shaping technique can further deteriorate the material and weaken it even more because of the presence of these defects.  Companies market strips of fibrous materials obtained by a method of impregnating unidirectional fibers by passing the fibers continuously in a molten bath of thermoplastic polymer containing an organic solvent such as benzophenone.  For example, US Pat. No. 4,541,884 to Imperial Chemical Industries can be referred to.  The presence of the organic solvent makes it possible in particular to adapt the viscosity of the molten mixture and to ensure a good coating of the fibers.  The fibers thus pre-impregnated are then shaped.  They may for example be cut into strips of different widths and then placed under a press, then heated to a temperature above the melting temperature of the polymer to ensure the cohesion of the material and in particular the adhesion of the polymer to the fibers.  This method of impregnation and shaping makes it possible to produce structural parts with high mechanical strength.  One of the disadvantages of this technique lies in the heating temperature required to obtain these materials.  The melting temperature of the polymers depends in particular on their chemical nature.  It can be relatively high for poly (methyl methacrylate) (PMMA) polymers, or even very high for poly (phenylene sulfide) (PPS), poly (ether ether ketone) (PEEK) or poly ( ether ketone ketone) (PEKK) for example.  The heating temperature can therefore increase to temperatures above 250 ° C, Ref: 0390-ARK43 and even higher than 350 ° C, temperatures that are much higher than the boiling point and the flash point of the solvent, which are respectively of 305 ° C and 150 ° C for benzophenone.  In this case, there is a sudden departure of the solvent inducing a high porosity within the fibers and therefore causing the appearance of defects in the composite material.  The process is therefore difficult to reproduce and involves risks of explosion endangering the operators.  Finally, the use of organic solvents is to be avoided for environmental and health and safety reasons.  The document EP 0 406 067, filed with the joint names of Atochem and the French State, as well as the document EPO 201 367 describe a technique for impregnating a fluidized bed of polymer powder.  The fibers enter a closed fluidization tank where they are optionally separated from each other by means of rollers or corrugated rolls, the fibers being electrostatically charged by friction in contact with these rollers or rolls.  This electrostatic charge allows the polymer powder to stick to the surface of the fibers and thus to impregnate them.  Regarding the shaping of preimpregnated fibrous materials in the form of calibrated ribbons, suitable for the manufacture of three-dimensional composite parts by automatic removal by means of a robot, it is generally carried out in post-processing.  The quality of the pre-impregnated fibrous material ribbons, and therefore the quality of the final composite material, depends not only on the homogeneity of the impregnation of the fibers and therefore on the control and reproducibility of the porosity of the fibrous material. pre-impregnated, but also the size and more particularly the width and thickness of the final ribbons.  Regularity and control of these two dimensional parameters make it possible to improve the mechanical strength of the materials.  Currently, regardless of the process used for the impregnation of fibrous materials, the manufacture of ribbons of small width, that is to say of width less than 100mm, generally requires a slitting (that is to say -describe a cut) of strips of width greater than 500 mm, also called tablecloths.  The ribbons thus dimensioned are then taken back to be deposited by a robot using a head.  Ref: 0390-ARK43 [0018] In addition, rolls of webs not exceeding a length of the order of 1 km, the ribbons obtained after cutting are generally not long enough to manufacture some large size materials during the removed by robot.  The ribbons must therefore be roped to obtain a longer length, creating extra thicknesses.  These extra thicknesses lead to the appearance of heterogeneities that are detrimental to obtaining good quality composite materials.  Current techniques for impregnating fibrous materials and shaping such fibrous pre-impregnated materials in the form of calibrated ribbons therefore have several disadvantages.  For example, it is difficult to homogeneously heat a molten mixture of thermoplastic polymers in a die and at the outlet of the die to the core of the material, which alters the quality of the impregnation.  In addition, the difference in temperature existing between the fibers and a molten mixture of polymers at the level of the impregnation die also alters the quality and homogeneity of the impregnation.  The use of organic solvents usually involves the appearance of defects in the material as well as environmental, health and safety risks in general.  The shaping, by high-temperature post-treatment of the pre-impregnated fibrous material in the form of strips, remains difficult because it does not always allow a homogeneous distribution of the polymer within the fibers, which leads to obtaining a material of lower quality, with poorly controlled porosity.  The splitting of webs for obtaining calibrated ribbons and the splicing of these ribbons induces an additional cost of manufacture.  Slitting also generates significant dust problems that pollute the ribbons of pre-impregnated fibrous materials used for robot removal and can cause malfunctions of robots and / or imperfections on the composites.  This potentially leads to robot repair costs, a shutdown of production and the scrapping of non-compliant products.  Finally, during the slitting step, a not insignificant amount of fibers is deteriorated, inducing a loss of properties, and in particular a reduction of the mechanical strength and conductivity, ribbons of preimpregnated fibrous material.  (Technical problem) Ref: 0390-ARK43 [0020] The object of the invention is therefore to remedy at least one of the drawbacks of the prior art.  The invention aims in particular to provide a method of manufacturing a preimpregnated fibrous material, combining an impregnation technique and a continuous shaping technique, in order to avoid any post-treatment step of the fibrous material, and obtaining a preimpregnated fibrous material having homogeneous fiber impregnation and controlled dimensions, with controlled and reproducible porosity upon which the performance of the final composite part depends.  (BRIEF DESCRIPTION OF THE INVENTION) For this purpose, the subject of the invention is a process for manufacturing a preimpregnated fibrous material comprising a fibrous material made of continuous fibers and a thermoplastic polymer matrix, characterized in that said preimpregnated fibrous material is made of a single unidirectional ribbon or a plurality of unidirectional parallel ribbons and said method comprises the following steps: i.  impregnating said fibrous material in the form of a wick or several parallel locks, by said thermoplastic polymer being in the form of a powder in a fluidized bed, ii.  shaping said wick or said parallel locks of said fibrous material impregnated according to step i), by calendering by means of at least one heating radiator in the form of a single unidirectional ribbon or a plurality of unidirectional parallel ribbons with, in the latter case, said heating calender having a plurality of calendering grooves, preferably up to 200 calendering grooves, in accordance with the number of said ribbons and with a pressure and / or spacing between the rolls of said calender regulated by a slave system.  Thus, the hot calendering of the pre-impregnated bit or wicks, just downstream of the continuous impregnation device, by fluidized bed, makes it possible to homogenize the distribution of the polymer and the impregnation of the fibers, to control and to reduce the porosity rate within the preimpregnated fibrous material, and to obtain one or more ribbons of great length and of calibrated width and thickness.  The method according to the invention thus makes it possible to avoid the use of molten polymer, of excessive viscosity, the detrimental use of organic solvents, and also allows Ref: 0390-ARK43 to form ribbons of calibrated dimensions without use a slitting and splicing step.  According to other optional features of the method: - it further comprises a step iii) winding said ribbon or said ribbons on one or more coils, the number of coils being identical to the number of ribbons, a coil being assigned to each ribbon, - said impregnation step i) is completed by a step of covering said single wick or said plurality of parallel locks after impregnation with the powder according to step i), by a molten thermoplastic polymer, which may be identical or different from said polymer in the form of powder in a fluidized bed, said covering step being carried out before said calendering step ii), said molten polymer preferably being of the same nature as said polymer in powder form in a fluidized bed, preferably with said covering by extrusion at the head of square with respect to said single wick or to said plurality of parallel locks, said fluidized-bed powder polymer is a thermoplastic polymer or a mixture of thermoplastic polymers, said thermoplastic polymer or thermoplastic polymer blend further comprises carbon-containing fillers, in particular carbon black or carbon nanofillers, preferably selected from carbon nanofillers, in particular graphenes and / or carbon nanotubes and / or carbon nanofibrils or mixtures thereof, the thermoplastic polymer or thermoplastic polymer blend further comprises liquid crystal polymers or polybutylene cyclized terephthalate), or mixtures thereof, as an additive, said polymer, or mixture of thermoplastic polymers, is selected from amorphous polymers whose glass transition temperature is such that Te 80 ° C and / or from semi-crystalline polymers. crystallites whose melting point T f is 150 ° C, - the polymer thermoplastic or thermoplastic polymer blend is selected from: polyaryl ether ketones (PAEK), particularly poly (ether ether ketone) (PEEK); polyaryl ether ketone ketone (PAEKK), in particular poly (ether ketone ketone) (PEKK); aromatic polyether-imides (PEI) Ref: 0390-ARK43; polyaryl sulfones, in particular polyphenylene sulfones (PPSU); polyarylsulfides, in particular polyphenylene sulfides (PPS); polyamides (PA), in particular aromatic polyamides optionally modified by urea units; polyacrylates, in particular polymethyl methacrylate (PMMA); or fluoropolymers, in particular polyvinylidene fluoride (PVDF); and mixtures thereof, - said fibrous material comprises continuous fibers selected from carbon, glass, silicon carbide, basalt, silica fibers, natural fibers, in particular flax or hemp, sisal, silk, or cellulosic materials, in particular viscose, or thermoplastic fibers with a glass transition temperature Tg greater than the Tg of said polymer or said polymer mixture when it is amorphous or has a melting temperature Tf greater than the Tf of said polymer or said mixture of polymers when the latter is semi-crystalline, or a mixture of two or more of said fibers, preferably a mixture of carbon fibers, glass or silicon carbide, in particular carbon fibers, the volume ratio said polymer or mixture of polymers with respect to said fibrous material varies from 40 to 250%, preferably from 45 to 125% and more preferably from 45 to 80%; olume of said polymer or said polymer mixture with respect to said fibrous material varies from 0.2 and 15%, preferably between 0.2 and 10% and more preferably from 0.2 and 5%, - the calendering stage ii) is carried out by means of a plurality of heating calenders, - said heating shell (s) of step ii) comprises (include) an integrated induction heating system coupled to the presence of carbonaceous charges in said thermoplastic polymer or mixture of thermoplastic polymers, said heating shell (s) of step ii) is (are) coupled to a rapid complementary heating device located before and / or or after said (each) calender, in particular a microwave or induction heating device coupled to the presence of carbonaceous fillers in said polymer or in said polymer mixture, or an IR infrared heater, Ref: 0390-ARK43 or Laser or by contact t direct with another heat source such as a flame.  The invention also relates to a unidirectional ribbon of preimpregnated fibrous material, in particular tape wound on a reel, characterized in that it is obtained by a method as defined above.  According to an optional feature, the ribbon has a width and a thickness adapted to robot removal in the manufacture of parts in three dimensions, without the need for splitting, and preferably has a width of at least 5 mm and can go up to 100mm, preferably between 5 and 50mm and even more preferably between 5 and 10mm.  The invention also relates to a use of the method as defined above for the manufacture of calibrated ribbons suitable for the manufacture of composite parts in three dimensions by automatic removal of said ribbons by means of a robot.  The invention further relates to a use of the tape as defined above in the manufacture of parts in three dimensions.  Said manufacture of said composite parts relates to the fields of transport, in particular automobile, civil or military aeronautics, nautical, railway; renewable energy, in particular wind turbine, tidal turbine, energy storage devices, solar panels; thermal protection panels; sports and recreation, health and medical, ballistics with weapon or missile parts, security and electronics.  The invention also relates to a three-dimensional composite part, characterized in that it results from the use of at least one unidirectional tape of preimpregnated fibrous material as defined above.  The invention finally relates to a unit for implementing the manufacturing method as defined above, said unit being characterized in that it comprises: a) a device for continuously impregnating a wick or a plurality of parallel locks of fibrous material comprising a fluidized bed for polymer powder, Ref: 0390-ARK43 b) a continuous calendering device of said wick or parallel locks, with shaping, in the form of of a single ribbon or in the form of several unidirectional parallel ribbons, comprising: b1) at least one heating calender, in particular several series of heated calanders, said calender having a calendering groove or several calendering grooves, and preferably in this case. last case having up to 200 calendering grooves, b2) a system for regulating the pressure and / or spacing between calendering rollers.  According to other optional features of said unit: - it further comprises a winding device tapes fibrous material pre-impregnated, having a number of coils identical to the number of ribbons, a coil being assigned to each ribbon said impregnation device further comprises and following said fluidised bed tank, a device for covering said wick of impregnated fibrous material or said wicks impregnated according to step i), by a molten polymer, preferably said device covering device comprising an extrusion device at the right angle with respect to said wick or with respect to said parallel wicks, said heating shell (s) comprises (include) an integrated heating system by induction, said heated radiator grille (s) is (are) coupled to a complementary rapid heating device, located before and / or after said (each) alandre, said rapid heating device being chosen from a microwave or induction device, in particular when it is coupled to the presence of carbonaceous charges, or an IR or laser device or other device allowing direct contact with the heat source , such as a flame device.  Other features and advantages of the invention will appear on reading the description given by way of illustrative and nonlimiting example, with reference to the appended figures, which represent: FIG. 1, a diagram of a unit for implementing the process for manufacturing a preimpregnated fibrous material according to the invention, Ref: 0390-ARK43 - FIG. 2, a sectional diagram of two rollers constituting a calender as used in FIG. unit of Figure 1.  Detailed description of the invention Polymeric matrix Thermoplastic, or thermoplastic polymer, is understood to mean a generally solid material at room temperature, which may be crystalline, semi-crystalline or amorphous, and which softens upon increasing of temperature, in particular after passing its glass transition temperature (Tg) and flows at a higher temperature and can observe a frank fusion at the passage of its so-called melting temperature (Tf) (when it is semi-crystalline) and which becomes solid again when the temperature falls below its melting temperature and below its glass transition temperature.  Regarding the polymer of constitution of the impregnating matrix of the fibrous material, it is advantageously a thermoplastic polymer or a mixture of thermoplastic polymers.  This polymer or mixture of thermoplastic polymers is crushed in powder form so that it can be used in a fluidized bed.  The powder particles have an average diameter of preferably less than 125 μm in order to be able to penetrate the fiber strand or strands.  [0034] Optionally, the thermoplastic polymer or thermoplastic polymer blend further comprises carbonaceous fillers, in particular carbon black or carbon nanofillers, preferably chosen from carbon nanofillers, in particular graphenes and / or nanotubes. of carbon and / or carbon nanofibrils or mixtures thereof.  These charges make it possible to conduct electricity and heat, and consequently make it possible to improve the lubrication of the polymer matrix when it is heated.  According to another variant, the thermoplastic polymer or thermoplastic polymer blend may further comprise additives, such as liquid crystal polymers or cyclized poly (butylene terephthalate), or mixtures containing them, such as commercialized CBT100 resin. by CYCLICS CORPORATION.  These additives make it possible in particular to fluidify the polymer matrix in the molten state, for better penetration into the core of the fibers.  Depending on the nature of the polymer, or mixture of thermoplastic polymers, used to make the impregnation matrix, in particular its melting point, one or other of these additives will be chosen.  Advantageously, the thermoplastic polymer or thermoplastic polymer mixture is selected from amorphous polymers whose glass transition temperature is such that Te 80 ° C and / or from semi-crystalline polymers whose melting temperature T f is 150 ° C.  More particularly, the thermoplastic polymers used in the constitution of the impregnating matrix of the fibrous material may be chosen from - polymers and copolymers of the family of polyamides (PA), such as high density polyamide, polyamide 6 (PA-6), polyamide 11 (PA-11), polyamide 12 (PA-12), polyamide 6. 6 (PA-6. 6), the polyamide 4. 6 (PA-4. 6), the polyamide 6. (PA-6. 10), the polyamide 6. 12 (PA-6. 12), aromatic polyamides, optionally modified with urea units, in particular polyphthalamides and aramid, and block copolymers, in particular polyamide / polyether, polyureas, in particular aromatic polymers, and polymers and copolymers of the family. acrylics such as polyacrylates, and more particularly polymethyl methacrylate (PMMA) or its derivatives - polymers and copolymers of the polyaryletherketone (PAEK) family such as polyether etherketone (PEEK), or polyaryletherketonesketones (PAEKK) such as polyetherketone ketone (PEKK) or their derivatives, aromatic polyetherimides (PEI), polyarylsulfides, in particular polyphenylene sulfides (PPS), polyarylsulphones, in particular polyphenylene sulfones (PPSU) - polyolefins, in particular polypropylene (PP); polylactic acid (PLA), polyvinyl alcohol (PVA), fluorinated polymers, in particular polyvinylidene fluoride (PVDF), or polytetrafluoroethylene (PTFE) or polychlorotrifluoroethylene (PCTFE), and their mixtures.  Ref: 0390-ARK43 [0038] Preferably, the polymers constituting the matrix are chosen from thermoplastic polymers having a high melting temperature Tf, namely from 150 ° C. and higher, such as polyamides (PA), in particular aromatic polyamides optionally modified with urea units, and copolymers thereof, polymethyl methacrylate (PPMA) and its copolymers, polyetherimides (PEI), polyphenylene sulphide (PPS), polyphenylene sulphone ) (PPSU), polyetherketoneketone (PEKK), polyetheretherketone (PEEK), fluorinated polymers such as polyvinylidene fluoride (PVDF).  For the fluoropolymers, it is possible to use a homopolymer of vinylidene fluoride (VDF of formula CH2 = CF2) or a copolymer of VDF comprising by weight at least 50% by weight of VDF and at least one other monomer copolymerizable with the VDF.  The VDF content must be greater than 80% by weight, or even better 90% by weight, to ensure good mechanical strength to the structural part, especially when subjected to thermal stresses.  The comonomer may be a fluorinated monomer such as, for example, vinyl fluoride.  For structural parts to withstand high temperatures, in addition to the fluorinated polymers, is advantageously used according to the invention PAEK (PolyArylEtherKetone) such as polyether ketone PEK, poly (ether ether ketone) PEEK, poly (ether ketone ketone) PEKK, Poly (ether ketone ether ketone ketone) PE KEKK etc.  Fibrous material: [0041] As regards the fibers of constitution of the fibrous material, they are in particular fibers of mineral, organic or vegetable origin.  Among the fibers of mineral origin, mention may be made of carbon fibers, glass fibers, basalt fibers, silica fibers, or silicon carbide fibers, for example.  Among the fibers of organic origin, mention may be made of thermoplastic or thermosetting polymer-based fibers, such as aromatic polyamide fibers, aramid fibers or polyolefin fibers, for example.  Preferably, they are based on thermoplastic polymer and have a glass transition temperature Tg greater than the Tg of the polymer or thermoplastic polymer mixture of constitution of the impregnation matrix when the latter is amorphous, or a melting temperature Tf greater than the Tf of the polymer or thermoplastic polymer mixture of constitution of the impregnation matrix Ref: 0390-ARK43 when the latter is semi-crystalline.  Thus, there is no risk of fusion for the organic fibers constituting the fibrous material.  Among the fibers of vegetable origin, mention may be made of natural fibers based on flax, hemp, silk, especially spider, sisal, and other cellulosic fibers, in particular viscose fibers.  These fibers of plant origin can be used pure, treated or coated with a coating layer, in order to facilitate the adhesion and impregnation of the thermoplastic polymer matrix. These constituent fibers can be used. alone or in mixtures.  Thus, organic fibers may be mixed with the mineral fibers to be impregnated with thermoplastic polymer and form the preimpregnated fibrous material.  The fibers are optionally single-strand, multi-strand or a mixture of both, and may have several grammages.  They can also have several geometries.  Thus, they may be in the form of short fibers, which then make up the felt or nonwovens which may be in the form of strips, sheets, braids, locks or pieces, or in the form of continuous fibers, which make up the 2D fabrics. , fibers or strands of unidirectional fibers (UD) or nonwoven fibers.  The fibers constituting the fibrous material may also be in the form of a mixture of these reinforcing fibers of different geometries.  Preferably, the fibers are continuous.  Preferably the fibrous material is constituted by continuous fibers of carbon, glass or silicon carbide or their mixture, in particular carbon fibers.  It is used in the form of a lock or several locks.  According to the polymer volume ratio relative to the fibrous material, it is possible to produce so-called pre-impregnated materials "ready to use" or so-called "dry" pre-impregnated materials.  In pre-impregnated materials known as "ready to use", the polymer or mixture of thermoplastic impregnating polymers is distributed uniformly and homogeneously around the fibers.  In this type of material, the thermoplastic impregnating polymer must be distributed as homogeneously as possible within the fibers in order to obtain a minimum of porosities, ie voids between the fibers.  Indeed, the presence of porosities in this type of material can act as points of concentration of stress, when placed under mechanical tensile stress for example, and which then form points Ref: 0390-ARK43 of initiation of rupture of the preimpregnated fibrous material and weaken it mechanically.  A homogeneous distribution of the polymer or polymer mixture thus improves the mechanical strength and the homogeneity of the composite material formed from these preimpregnated fibrous materials.  Thus, in the case of pre-impregnated materials known as "ready to use", the volume ratio of the polymer or mixture of thermoplastic polymers with respect to the fibrous material varies from 40 to 250%, preferably from 45 to 125%, and more preferably 45 to 80%.  The so-called "dry" preimpregnated fibrous materials, in turn, comprise pores between the fibers and a smaller amount of thermoplastic impregnating polymer which covers the surface fibers to hold them together.  These "dry" prepreg materials are suitable for the manufacture of preforms for composite materials.  These preforms can then be used to make the infusion of thermoplastic resin or thermosetting resin for example.  In this case, the porosities make it possible to facilitate the subsequent transport of the infused polymer resin within the preimpregnated fibrous material, in order to improve the final properties of the composite material and in particular its mechanical cohesion.  In this case, the presence of the thermoplastic impregnating polymer on the so-called "dry" preimpregnated fibrous material makes it possible to make the infusion resin compatible.  Thus, in the case of so-called "dry" preimpregnated materials, the volume ratio of the polymer or the mixture of polymers with respect to the fibrous material advantageously varies from 0.2 to 15%, preferably from 0.2 to and 10% and more preferably 0.2 and 5%.  In this case we speak of polymeric web, low weight, deposited on the fibrous material to hold the fibers together.  The method for manufacturing a fibrous material according to the invention advantageously comprises two steps: a first step of impregnating the fibrous material with the thermoplastic polymer, then a shaping step of the fibrous material pre-impregnated in the form of one or more unidirectional ribbons whose width and thickness are calibrated.  Impregnation step: Ref: 0390-ARK43 [0051] The manufacturing method and the implementation unit of this method are described below, with reference to FIG. 1 which schematizes, in a very simplified manner, the elements constituting this unit 100.  Advantageously, the impregnation step of the fibrous material is carried out by passing one or more locks in a continuous impregnation device, comprising a fluidised bed of polymeric powder bed.  Each wick to be impregnated is then unwound from a device 10 with reels 11 under the traction generated by cylinders (not shown).  Preferably, the device 10 comprises a plurality of reels 11, each reel for unwinding a wick to impregnate.  Thus, it is possible to impregnate several strands of fibers simultaneously.  Each reel 11 is provided with a brake (not shown) so as to apply a tension on each strand of fibers.  In this case, an alignment module 12 allows to arrange the fiber locks parallel to each other.  In this way the fiber locks can not be in contact with each other, which makes it possible to avoid mechanical degradation of the fibers in particular.  The fiber wick or the parallel fiber locks then pass into a fluidized bed tank 22, as described in patent EP0406067.  The polymer powder (s) is suspended in a gas G (air for example) introduced into the tank and circulating in the tank through a hopper 21.  The wick or wicks are circulated in this fluidized bed 22.  The average diameter of the polymer powder particles in the fluidized bed is preferably less than 125 μm in order to penetrate the fiber lock.  This impregnation is performed to allow adhesion of the polymeric powder on the fibers.  The or wicks pre-impregnated with the powder, then emerge from the tank to go to a heating calendering device, with possibility of preheating before calendering and optional heating post-calendering.  Optionally, this impregnation step can be completed by a step of covering the wick or pre-impregnated wicks, just at the outlet of the impregnation vessel 20 by the fluidized-bed powder 22, and just before the calendering shaping step.  For this, the outlet lock of the fluidization tank (fluidized bed 22) can be connected to a covering device 30 which can comprise a cover angle head, as is also Ref: 0390-ARK43 described in the patent EP0406067.  More particularly, said covering device comprises a square head supplied with thermoplastic polymer melted by an extruder 30.  The overlay polymer may be the same or different from the fluidized bed polymer powder.  Preferably, it is of the same nature.  Such a covering not only makes it possible to complete the fiber impregnation step in order to obtain a final polymer volume content in the desired range, in particular for obtaining good quality "ready-to-use" fibrous materials, but it also makes it possible to improve the performance of the composite material obtained.
    [0002] Shaping step [0056] As soon as it (their) out of the fluidization tank 20, the wick (the parallel locks) pre-impregnated, optionally covered (s) with a molten polymer, is (are) put (s) ) shaped as a single unidirectional ribbon or a plurality of parallel unidirectional ribbons, by means of a continuous calender device comprising one or more heating calandres. So far hot calendering could not be considered for a shaping step but only for a finishing step because it did not allow heating at sufficient temperatures, especially when the polymer, or mixture of thermoplastic polymers, impregnation comprises polymers with a high melting temperature. Advantageously, the heating calenders of the calendering device are coupled to rapid heating means that heat the material not only at the surface but also at the core. The mechanical stress of the calenders coupled to these rapid heating means makes it possible to eliminate the presence of porosities and to homogeneously distribute the polymer, especially when the fibrous material is a so-called "ready-to-use" material. Advantageously, this hot calendering not only allows the impregnating polymer to be heated so that it penetrates, adheres and uniformly covers the fibers, but also to control the thickness and the width of the strip or ribbons. fibrous material prepreg. To be able to make a plurality of unidirectional parallel ribbons, that is to say as many ribbons as pre-impregnated parallel strands, passed in the fluidized bed, heating calenders, referenced 51, 52, 53 on the diagram Ref: 0390-ARK43 Figure 1, advantageously comprise a plurality of calendering grooves, in accordance with the number of ribbons. This number of grooves can for example go up to 200. A SYST slave system also allows to regulate the pressure and / or spacing E between the rollers 71, 75 of the calender 70, so as to control the thickness ep ribbons. Such a shell 70 is shown schematically in Figure 2 described below. The calendering device comprises at least one heating radiator 51. Preferably, it comprises a plurality of heating radiators 51, 52, 53 connected in series. The fact of having several calender in series makes it possible to pack the porosities in the material and to reduce their rate. This plurality of calenders is therefore important when it is desired to produce so-called "ready-to-use" fibrous materials. On the other hand, to manufacture so-called "dry" fibrous materials it is possible to be satisfied with a lower number of calenders or even a single calender. Advantageously, each calender of the calendering device has an integrated heating system by induction, in order to heat the polymer or mixture of thermoplastic polymers. Advantageously, when the polymer or mixture of polymers comprises carbon-containing fillers, such as carbon black or carbon nanofillers, preferably chosen from carbon nanofillers, in particular graphenes and / or carbon nanotubes and / or carbon nanofibrils or their mixtures, the induction heating effect is amplified by the presence of these charges which then lead the heat to the core of the material. Advantageously, each calender 51, 52, 53 of the device is coupled to a rapid heating device 41, 42, 43, located before and / or after each calender, in order to quickly transmit thermal energy to the material. and perfecting the impregnation of the fibers with the molten polymer. The rapid heating device may for example be chosen from the following devices: a microwave or induction device, an IR or laser infrared device or other device allowing direct contact with the heat source such as a flame device. A microwave or induction device is very advantageous, in particular when it is coupled to the presence of carbon nanofillers in the polymer or polymer mixture since the carbon nanofillers amplify the heating effect and transmit it to the core of the material. Ref: 0390-ARK43 [0064] According to an alternative embodiment, it is also possible to combine several of these heating devices. Optionally, a subsequent step is to wind the tape or pre-impregnated and shaped tapes. For this, the unit 100 for implementing the method comprises a winding device 60 comprising as many coils 61 as ribbons, a coil 61 being assigned to each ribbon. A splitter 62 is generally provided to deflect the pre-impregnated ribbons to their respective coils 61, while preventing the ribbons touching to avoid any degradation. Figure 2 shows schematically the detail of the grooves 73 of a calender 70 sectional view. A calender 70 comprises an upper roller 71 and a lower roller 75. One of the rollers, for example the upper roller 71, comprises a crenellated portion 72, while the other roller, i.e., the lower roller 75 in the example comprises a grooved portion 76, the shape of the grooves being complementary to the shape of the protruding portions 72 of the upper roller. The distance E between the rollers 71, 75 and / or the pressure exerted by the two rollers against each other makes it possible to define the dimensions of the grooves 73, and in particular their thickness ep and of width I. Each groove 73 is provided to house a bit of fiber which is then pressed and heated between the rollers. The wicks then turn into parallel unidirectional ribbons whose thickness and width are calibrated by the grooves 73 of the calenders. Each calender advantageously comprises a plurality of grooves, the number of which can be up to 200, so as to produce as many ribbons as there are grooves and pre-impregnated locks. The calendering device further comprises a central device, referenced SYST in FIG. 1, controlled by a computer program provided for this purpose, which makes it possible to simultaneously regulate the pressure and / or the spacing of the calendering rollers of all the The one-way ribbon (s) thus produced has (s) a width I and a thickness ep adapted for robot removal in the manufacture of parts in three parts. dimensions, without slitting. The width of the ribbon (s) is advantageously between 5 and 100 mm, preferably between 5 and 50 mm, and even more preferably between 5 and 10 mm. The process for manufacturing a preimpregnated fibrous material which has just been described thus makes it possible to produce fibrous materials pre-impregnated with a high productivity Ref: 0390-ARK43, while permitting homogeneous impregnation of the fibers and the control and reproducibility of the porosity, and thus the control and reproducibility of the performances of the final composite article in question. The homogeneous impregnation around the fibers and the absence of porosities are ensured by the fluidized bed impregnation stage coupled with the use of a mechanical stress shaping device, itself coupled fast heating that allows to heat the material on the surface but also to the heart. The materials obtained are semi-finished products in the form of ribbons calibrated in thickness and width and which are used for the manufacture of structural parts in three dimensions in the transport sectors such as automotive, civil aviation or military, nautical, or railway, renewable energy, in particular wind turbine, tidal turbine, energy storage devices, solar panels; thermal protection panels; sports and recreation, health and medical, armament and ballistics (weapon or missile parts), security, by a process that may be the removal of bands assisted by a robot head for example , and known as the AFP method (from the acronym "Automatic Fiber Placement"). This method therefore allows to continuously produce tapes of calibrated dimensions and long, so that it avoids slitting and splicing expensive and detrimental to the quality of composite parts manufactured later. The economics of eliminating the slitting step is about 30-40% of the total cost of producing a ribbon of preimpregnated fibrous material. The combination of rapid heating devices with hot calenders facilitates the shaping of ribbons to the desired dimensions and significantly increases the production rate of these ribbons compared to conventional shaping processes. Moreover, this combination makes it possible to densify the material by completely eliminating the porosities in so-called "ready-to-use" fibrous materials. The rapid heating devices also allow the use of many polymer grades, even the most viscous, which can cover all ranges of mechanical strength desired. Ref: 0390-ARK43 [0072] For the specific manufacture of so-called "dry" fibrous material ribbons, the fluidized bed impregnation step makes it possible to obtain a uniformly controlled and reproducible homogeneous weight of polymers, with a rate of preferred polymer deposited of the order of 5 to 7 g / m. The method thus makes it possible to produce calibrated ribbons of preimpregnated fibrous material suitable for the manufacture of composite parts in three dimensions, by automatic removal of said ribbons by means of a robot. Ref: 0390-ARK43
    权利要求:
    Claims (25)
    [0001]
    REVENDICATIONS1. A method of manufacturing a preimpregnated fibrous material comprising a continuous fiber fibrous material and a thermoplastic polymer matrix, characterized in that said preimpregnated fibrous material is made of a single unidirectional ribbon or a plurality of unidirectional parallel ribbon and in that said method comprises the following steps: i) impregnating said fibrous material in the form of a wick or several parallel locks, by said thermoplastic polymer in the form of a powder in a fluidized bed (22), ii ) shaping of said wick or said parallel locks of said impregnated fibrous material according to step i), by calendering by means of at least one heating radiator (51, 52, 53) in the form of a single unidirectional ribbon or a plurality of unidirectional parallel ribbons with, in the latter case, said heating calender comprising a plurality of grooves (73) of calendering, preferably up to 200 calendering grooves, in accordance with the number of said ribbons and with a pressure and / or spacing between the rollers of said calender controlled by a slave system.
    [0002]
    2. Method according to claim 1, characterized in that it further comprises a step iii) of winding said ribbon or said ribbons on one or more coils (61), the number of coils being identical to the number of ribbons, a coil being assigned to each ribbon.
    [0003]
    3. Method according to claim 1 or 2, characterized in that said impregnation step i) is completed by a step of covering said single wick or said plurality of parallel locks after impregnation with the powder according to step i) by a molten thermoplastic polymer, which may be identical or different from said polymer in the form of powder in a fluidized bed, said covering step being carried out before said calendering step Ref: 0390-ARK43ii), said molten polymer preferably being of the same nature as said fluidized-bed powder polymer, preferably with said overlap (30) at the head-end relative to said single wick or said plurality of parallel wicks.
    [0004]
    4. Method according to one of claims 1 to 3, characterized in that said polymer in the form of fluidized bed powder is a thermoplastic polymer or a mixture of thermoplastic polymers.
    [0005]
    5. Method according to claim 4, characterized in that said thermoplastic polymer or mixture of thermoplastic polymers further comprises carbonaceous fillers, in particular carbon black or carbon nanofillers, preferably chosen from carbon nanofillers, in particular graphenes. and / or carbon nanotubes and / or carbon nanofibrils or mixtures thereof.
    [0006]
    6. Method according to one of claims 4 or 5, characterized in that the thermoplastic polymer or mixture of thermoplastic polymers further comprises liquid crystal polymers or cyclized poly (butylene terephthalate), or mixtures containing it, as additive .
    [0007]
    7. Method according to one of claims 1 to 6, characterized in that said polymer, or mixture of thermoplastic polymers, is selected from amorphous polymers whose glass transition temperature is such that Te 80 ° C and / or among semi-crystalline polymers whose melting temperature Tf is 150 ° C.
    [0008]
    8. Process according to claim 7, characterized in that the thermoplastic polymer or thermoplastic polymer blend is selected from: polyaryl ether ketones (PAEK), in particular poly (ether ether ketone) (PEEK); polyaryl ether ketone ketone (PAEKK), in particular poly (ether ketone ketone) (PEKK); aromatic polyetherimides (PEI); Ref: 0390-ARK43Polyaryl sulfones, especially polyphenylene sulfones (PPSU); polyarylsulfides, in particular polyphenylene sulfides (PPS); polyamides (PA), in particular aromatic polyamides optionally modified by urea units; polyacrylates, in particular polymethyl methacrylate (PMMA); or fluoropolymers, in particular polyvinylidene fluoride (PVDF); and their mixtures.
    [0009]
    9. Method according to one of claims 1 to 8, characterized in that said fibrous material comprises continuous fibers selected from carbon fibers, glass, silicon carbide, basalt, silica, natural fibers in particular flax or hemp, sisal, silk, or cellulosic, in particular viscose, or thermoplastic fibers with a glass transition temperature Tg greater than the Tg of said polymer or said polymer mixture when the latter is amorphous or with a temperature of melting Tf greater than the Tf of said polymer or said polymer mixture when it is semi-crystalline, or a mixture of two or more of said fibers, preferably a mixture of carbon fibers, glass or silicon carbide, in particular carbon fibers.
    [0010]
    10. Method according to one of claims 1 to 9, characterized in that the volume ratio of said polymer or polymer mixture relative to said fibrous material ranges from 40 to 250%, preferably 45 to 125% and more preferably 45 to 125%. at 80%.
    [0011]
    11. Method according to one of claims 1 to 9, characterized in that the volume ratio of said polymer or said polymer mixture relative to said fibrous material varies from 0.2 to 15%, preferably from 0.2 to 10%. % and more preferably 0.2 and 5%.
    [0012]
    12. Method according to one of claims 1 to 11, characterized in that the calendering step ii) is performed by means of a plurality of calenders (51, 52, 53) heating. Ref: 0390-ARK43
    [0013]
    13. Method according to one of claims 1 to 12, characterized in that said (or said) calender (s) heater (s) of step ii) comprises (include) an integrated induction heating system coupled to the presence of carbonaceous charges in said thermoplastic polymer or mixture of thermoplastic polymers.
    [0014]
    14. Method according to one of claims 1 to 13, characterized in that said (or said) calender (s) heating (s) of step ii) is (are) coupled (s) to a complementary heating device fast (41, 42, 43), located before and / or after said (each) calender (51, 52, 53), in particular a microwave heating device or induction coupled to the presence of carbonaceous charges in said polymer or in said polymer mixture, or an infrared heater IR, or laser or by direct contact with another heat source such as a flame.
    [0015]
    15. Unidirectional tape of preimpregnated fibrous material, in particular ribbon wound on a reel, characterized in that it is obtained by a process as defined according to one of claims 1 to 14.
    [0016]
    16. Tape according to claim 15, characterized in that it has a width (I) and a thickness (ep) adapted to robot removal in the manufacture of parts in three dimensions, without the need for slitting, and preferably a a width (I) of at least 5 mm and up to 100 mm, preferably between 5 and 50 mm and even more preferably between 5 and 10 mm.
    [0017]
    17. Use of the method as defined in one of claims 1 to 14, for the manufacture of calibrated ribbons suitable for the manufacture of composite parts in three dimensions, by automatically depositing said ribbons by means of a robot. Ref: 0390-ARK43
    [0018]
    18. Use of the ribbon of preimpregnated fibrous material, as defined in claim 15 or 16, in the manufacture of three-dimensional composite parts.
    [0019]
    19. Use according to claim 18, characterized in that said manufacture of said composite parts relates to the fields of transport, in particular automobile, civil or military aeronautical, nautical, railway; renewable energy, in particular wind turbine, tidal turbine, energy storage devices, solar panels; thermal protection panels; sports and recreation, health and medical, ballistics with weapon or missile parts, security and electronics.
    [0020]
    20. Three-dimensional composite part, characterized in that it results from the use of at least one unidirectional tape preimpregnated fibrous material as defined in claim 15 or 16.
    [0021]
    21. Unit for implementing the method as defined in one of claims 1 to 14, characterized in that it comprises: a) a device for continuous impregnation of a wick or a plurality of wicks parallel of fibrous material comprising a fluidized bed (20) for powdered polymer, (b) a continuous calendering device of said wick or parallel strands, shaped, in the form of a single ribbon or in the form of a plurality of unidirectional parallel ribbons, comprising: b1) at least one heating calender (51, 52, 53), in particular several heating calandres in series, said calender carrying a groove (73) for calendering or several calendering grooves, and preferably in the latter case having up to 200 grooves (73) of calendering, b2) a system for regulating the pressure and / or spacing between rollers (71, 75) calender. Ref: 0390-ARK43
    [0022]
    22. Unit according to claim 21, characterized in that it further comprises a device (60) for winding ribbons of preimpregnated fibrous material, comprising a number of coils (61) identical to the number of ribbons, a reel being assigned to each ribbon.
    [0023]
    23. Unit according to claim 21 or 22, characterized in that said impregnation device further comprises and following said fluidized bed tank, a device for covering said wick of impregnated fibrous material or said wicks impregnated according to step i), by a molten polymer, preferably said covering device comprising an extrusion device (30) at right angles to said wick or relative to said parallel wicks.
    [0024]
    24. Unit according to one of claims 21 to 23, characterized in that said heating (s) calender (s) (51, 52, 53) comprises (include) an integrated induction heating system.
    [0025]
    25. Unit according to one of claims 21 to 24, characterized in that said (said) calender (s) heating (s) is (are) coupled (s) to a complementary device for rapid heating (41, 42, 43 ), located before and / or after said (each) calender, said rapid heating device being chosen from a microwave or induction device, in particular when it is coupled to the presence of carbonaceous charges, or an IR or Laser device or another device allowing direct contact with the heat source, such as a flame device. Ref: 0390-ARK43
    类似技术:
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    同族专利:
    公开号 | 公开日
    WO2015121583A2|2015-08-20|
    EP3446845B1|2020-10-28|
    FR3017329B1|2016-07-29|
    KR101909362B1|2018-12-19|
    EP3105025A2|2016-12-21|
    KR20160110445A|2016-09-21|
    US10974418B2|2021-04-13|
    JP6450773B2|2019-01-09|
    WO2015121583A3|2015-10-08|
    JP2017507045A|2017-03-16|
    ES2749863T3|2020-03-24|
    EP3446845A1|2019-02-27|
    US20170165875A1|2017-06-15|
    CN106163756A|2016-11-23|
    EP3105025B1|2019-08-07|
    ES2834886T3|2021-06-21|
    CN110126124A|2019-08-16|
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    CN111004519B|2019-12-20|2021-08-03|江门市德众泰工程塑胶科技有限公司|Low dielectric liquid crystal polyester composition and preparation method thereof|
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    优先权:
    申请号 | 申请日 | 专利标题
    FR1451137A|FR3017329B1|2014-02-13|2014-02-13|METHOD FOR MANUFACTURING PRE-IMPREGNATED FIBROUS MATERIAL OF FLUIDIZED BED THERMOPLASTIC POLYMER|FR1451137A| FR3017329B1|2014-02-13|2014-02-13|METHOD FOR MANUFACTURING PRE-IMPREGNATED FIBROUS MATERIAL OF FLUIDIZED BED THERMOPLASTIC POLYMER|
    ES15709241T| ES2749863T3|2014-02-13|2015-02-11|Method of manufacturing a fibrous material prepreg with a fluidized bed thermoplastic polymer|
    CN201910467619.6A| CN110126124A|2014-02-13|2015-02-11|Production pre-preg has the method for the fibrous material of thermoplastic polymer in a fluidized bed|
    KR1020167022068A| KR101909362B1|2014-02-13|2015-02-11|Method of producing a fibrous material pre-impregnated with thermoplastic polymer in a fluid bed|
    ES18200568T| ES2834886T3|2014-02-13|2015-02-11|Manufacturing process of a fibrous material pre-impregnated with thermoplastic polymer in a fluidized bed|
    JP2016551695A| JP6450773B2|2014-02-13|2015-02-11|Method for producing thermoplastic polymer pre-impregnated fiber material in a fluidized bed|
    US15/118,188| US10974418B2|2014-02-13|2015-02-11|Method of producing a fibrous material pre-impregnated with thermoplastic polymer in a fluid bed|
    PCT/FR2015/050331| WO2015121583A2|2014-02-13|2015-02-11|Method of producing a fibrous material pre-impregnated with thermoplastic polymer in a fluid bed|
    EP15709241.2A| EP3105025B1|2014-02-13|2015-02-11|Method of producing a fibrous material pre-impregnated with thermoplastic polymer in a fluid bed|
    EP18200568.6A| EP3446845B1|2014-02-13|2015-02-11|Method for producing a fibrous material pre-impregnated with thermoplastic polymer in a fluidised bed|
    CN201580019653.7A| CN106163756A|2014-02-13|2015-02-11|The method that pre-preg has the fibrous material of thermoplastic polymer is produced in fluid bed|
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