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Title:
A STABILIZED REINFORCING TEXTILE FABRIC AND A PRODUCTION METHOD THEREOF
Document Type and Number:
WIPO Patent Application WO/2019/027385
Kind Code:
A2
Abstract:
The present invention relates to stabilized reinforcing textile fabric and a production method thereof wherein the meltable thermoplastic resin is used as stabilizing resin which enables the resin used in stabilization application of non- crimp fabrics obtained from yarns comprising reinforcing fiber to impregnate more into the structure that is to better stabilize the reinforcing yarns. By means of stabilization, the spacing between the yarns comprising reinforcing yarn in the structure becomes more stable and controllable. Another objective of the present invention is to enable the reinforcing structure to provide ease of use during composite production and the composite material to have more homogenous strength values. Complex composite parts can easily be manufactured with the dry fabric obtained by means of this production method.

Inventors:
KORKMAZ, Deniz (Kordsa Teknik Tekstil A.Ş. Fatih Mah. Sanayici Cad. No:90 Alikahya, Izmit, Istanbul, 41310, TR)
CAKAL SARAC, Elcin (Kordsa Teknik Tekstil A.Ş. Fatih Mah. Sanayici Cad. No:90 Alikahya, Izmit/Kocaeli, 41310, TR)
BILGE, Egemen (Kordsa Teknik Tekstil A.Ş. Fatih Mah. Sanayici Cad. No:90 Alikahya, Izmit/Kocaeli, 41310, TR)
Application Number:
TR2017/050643
Publication Date:
February 07, 2019
Filing Date:
December 11, 2017
Export Citation:
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Assignee:
KORDSA TEKNIK TEKSTIL A.S. (Alikahya Mevkii Kordsa Teknoloji Merkezi, Izmit/Kocaeli, TR)
International Classes:
B29C70/06
Attorney, Agent or Firm:
ANKARA PATENT BUREAU LIMITED (Bestekar Sokak No: 10 Kavaklidere, Ankara, 06680, TR)
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Claims:
CLAIMS

1. A stabilized reinforcing textile fabric comprising at least one unidirectional reinforcing fiber layer formed of plurality of reinforcing fiber and a plurality of weft and warp yarns, and characterized in that the said weft and warp yarns are meltable thermoplastic yarns functioning as stabilizing resin.

2. A stabilized reinforcing textile fabric according to claim 1, characterized in that the said reinforcing yarns are comprised of carbon, glass, aramid, natural fiber, or a combination thereof.

3. A stabilized reinforcing textile fabric according to claim 1, characterized in that the said meltable thermoplastic yarns are comprised of polyamides, polyolefins, polyphthalamides, polyphenylene sulfide, polysulfone, polyether sulfone, polyarylene sulfide, fluoropolymer, polyacetal, polycarbonate, polyether ketone, polyether ether ketone, polyimide, polyether imide, polyarylene ether sulfone, styrenic polymer, polyesters or a combination thereof.

4. A stabilized reinforcing textile fabric according to claim 1, characterized in that the ratio of the said meltable thermoplastic yarns to the said reinforcing yarns is maximum 10% by weight.

5. A stabilized reinforcing yarn production method characterized by the steps of i. obtaining non-crimp fabric by feeding the reinforcing yarn at least unidirectionally to the system and including the thermoplastic yarn used in yarn form in certain distances and thickness depending on the reinforcing yarn:thermoplastic yarn ratio by weaving between the layers of the reinforcing yarn in weft and warp direction,

ii. impregnating the polymer in yarn form used in certain distances and thicknesses in order to adjust the ratio of the thermoplastic yarn in the textile material into the said structure by means of melting or softening.

6. A stabilized reinforcing textile fabric production method according to claim 5, characterized in that the said reinforcing yarns are comprised of carbon, glass, aramid, natural fiber, or a combination thereof.

7. A stabilized reinforcing textile fabric production method according to claim 5, characterized in that the said meltable thermoplastic yarns are comprised of polyamides, polyolefins, polyphthalamides, polyphenylene sulfide, polysulfone, polyether sulfone, polyarylene sulfide, fluoropolymer, polyacetal, polycarbonate, polyether ketone, polyether ether ketone, polyimide, polyether imide, polyarylene ether sulfone, styrenic polymer, polyesters or a combination thereof.

8. A stabilized reinforcing textile fabric production method according to claims 5-

7, characterized in that pressure in range of 0-100 bars is applied on the said non- crimp fabric in stage of melting or softening the said meltable thermoplastic yarn.

9. A stabilized reinforcing textile fabric production method according to claims 5-

8, characterized in that temperature in range of 0.01-60 minutes is applied on the said non-crimp fabric in stage of melting or softening the said meltable thermoplastic yarn.

10. A stabilized reinforcing textile fabric production method according to claims 5-9, characterized in that the said non-crimp fabric impregnated with the said molten thermoplastic yarn is cooled to a temperature below the glass transition temperature of the said thermoplastic yarn after the step of impregnating the said meltable thermoplastic yarn into the said fabric.

Description:
DESCRIPTION

A STABILIZED REINFORCING TEXTILE FABRIC AND A PRODUCTION METHOD THEREOF Field of the Invention

The present invention relates to a production method which is developed in order to be used as structural and visual material in all industrial fields, mainly aviation, defense industry, medical, marine and automotive, and which enables the non- crimp dry fabric formed with a yarn that is manufactured from at least unidirectional reinforcing fibers to be stabilized via the meltable thermoplastic yarn as resin. The layers forming the non-crimp fabric are formed by including the thermoplastic yarn in weft and warp direction into the system.

Background of the Invention

The composites are divided into two main categories, namely thermoset and thermoplastic. The thermoset composites are structures comprised of thermoset resin impregnated yarns manufactured from reinforcing fibers. The thermoplastic composites are structures comprised of thermoplastic resin impregnated yarns manufactured from reinforcing fibers. The composites are very popular today due to their lightweight, reducing emission values, and resistance against corrosion properties.

Today, the resin used in stabilizing textiles comprising reinforcing fiber used in composite sector is applied as liquid or powder. The bulk textile product which is obtained is then transformed into composite material which is the final product which production methods such as thermal and/or pressure forming.

In order to stabilize the textiles which are developed to produce thermoset and thermoplastic composite, yarns such as polyamides (PA) (polyamide 6 (PA6), polyamide 6,6 (PA66), polyphthalamide (PPA)), polyphenylene sulfide (PPS), polysulfone (PSU) polyarylenethersulfone, polyolefines (polyethylene (PE), polypropylene (PP) etc.), polyimide (PI), polyesters, preferably such as polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), polyether ether ketone (PEEK) can be used. In stabilizing process, powder and liquid resin can be applied with manual or automatic methods on the textile comprising reinforcing fiber. Especially, the powder application causes situations such as homogenization problem in distributing resin, difficulty in using optimum raw material, the high amount of waste occurring during production, and variance in strength value of the produced composite material.

The production method used in stabilizing the textiles comprising reinforcing fiber can be performed with discontinuous process or continuous process. In both discontinuous and continuous methods, even in case of feeding the powder and liquid resin is automatic, the resin/reinforcing fiber ratio cannot be applied in the desired accuracy since the amount of resin to be used is quite low. Variations occur in the resin amounts used in unit area.

Summary of the Invention

The objective of the present invention is to provide a production method which enables resin used in stabilization application of the non-crimp fabrics obtained from reinforcing fiber containing yarns to better impregnate into the structure, that is to better stabilize the reinforcing yarns relative to the conventional applications. In the application, the resin is applied in meltable thermoplastic yarn form. By means of stabilization, the spacing between the yarns comprising reinforcing yarn in the structure becomes more stable and controllable.

Another objective of the present invention is to enable the reinforcing structure to provide ease of use during composite production and the composite material to have more homogenous strength values. Complex composite parts can easily be manufactured with the dry fabric obtained by means of this production method. The most important advantage of the invention is to allow production of non- crimp fabric in standard weaving machines or hand looms without requiring multiaxial textiles production machine.

Detailed Description of the Invention

The examples of the "Stabilized reinforcing textile fabric" developed to fulfill the objective of the present invention are illustrated in the accompanying figure, in which;

Figure 1 The detailed view of biaxial structure which is subjected to the inventive stabilized reinforcing textile fabric production method when the angles of the layers of non-crimp fabric produced in weaving machine comprising fiber are considered. The components given in the figure are numbered and the numbers refer to the following:

A. Reinforcing yarn

B. Meltable thermoplastic yarn A stabilized reinforcing yarn production method comprises the steps of

i. Obtaining non-crimp fabric by feeding the reinforcing yarn at least unidirectionally to the system and including the thermoplastic yarn used in yarn form in certain distances and thickness depending on the reinforcing yarn:resin (thermoplastic yarn) ratio by weaving between the layers of the reinforcing yarn in weft and warp direction,

ii. Impregnating the polymer in yarn form used in certain distances and thicknesses in order to adjust the ratio of the thermoplastic yarn in the textile material into the said structure by means of melting or softening. The inventive reinforcing textile stabilization method; which is developed for composite part production, and enables the resin in form of a thermoplastic yarn used for stabilizing the non-crimp fabric comprising reinforcing yarn to be impregnated into the structure homogenously and deeply; comprises the steps of

- Obtaining thermoplastic yarn used in certain distances and thicknesses in yarn form depending on the ratio of reinforcing yarn and resin used in production of non-crimp fabric by the use of weaving machine,

- Increasing the temperature of the non-crimp fabric above softening or melting point of the thermoplastic yarn,

- Applying pressure (0-100 bar) on the fabric at this temperature,

- Applying pre-tensioning (0-5 g/tex) on the fabric at this temperature, - Enabling the thermoplastic resin in yarn form to be impregnated into the structure by melting in the fabric,

- Applying temperature for a time in range of 0.01-60 minutes,

- Obtaining the ready to use final product by cooling until it reaches a temperature below glass transition temperature (T g ) of the resin without pressure or under pressure.

For example, during the process of increasing the temperature of the non-crimp fabric manufactured by using weaving machine above softening or melting point of the thermoplastic yarn, it is enabled that the thermoplastic yarn used as resin is impregnated between the fibers of the reinforcing yarn by melting the thermoplastic yarn via hot roll, press or infrared heater. If the dry fabric stabilized with thermoplastic yarn will be used for thermoplastic composite production, it is preferred that the thermoplastic yarn to be used for stabilization is same as the resin used as matrix. In use for producing thermoset composite, the thermoplastic yarn used for stabilization is coated with suitable sizing material. Therefore, the thermoset resin used as matrix is compatible with the thermoplastic yarn. Epoxy resins, phenol resins, cyanate ester resins, vinyl ester resins, unsaturated polyester resins, and the resins obtained by modifying them can be given as example for thermoset resins to be used as matrix. In the said invention, the polymers used for stabilization process are manufactured from material selected from a group comprising polyamides (such as polyamide 6 (PA6), polyamide 6,6 (PA66), polyphthalamide (PPA) ), polyphenylene sulfide (PPS), polysulfone (PSU) (such as polyethersulfone (PES), poly arylenethersulf one), polyarylenesulfide, fluoropolymer, polyacetal, polycarbonate, styrenic polymer, polyolefins (such as polyethylene (PE), polypropylene (PP)), polyimide (PI), polyetherimide, polyesters preferably polyethylene terephthalate (PET) or polybutylene terephthalate (PBT), polyether ether ketone (PEEK), polyether ketone (PEK), or combinations thereof.

In the said invention, the weight of the meltable thermoplastic yarn used for stabilization can change between 10 to 2000 dtex.

In the said invention, the reinforcing yarn (A) used in producing the non-crimp fabric can be a yarn produced from a material selected from the group comprising glass fiber, carbon fiber, aramid fiber, natural fiber, or a combination thereof.

The term "non-crimp fabric" used in the invention is defined as a system comprised of one or more than one unidirectional fiber layers, and formed by holding these layers together by weaving with a yarn manufactured from thermoplastic polymer. When the angles of the unidirectional layers forming the non-crimp fabrics are considered, the fabrics can be unidirectional, biaxial, triaxial or multiaxial. The term "dtex" used in the invention is the weight in grams per 10.000 meters yarn.

In the inventive production method, the resin used for stabilization being in form of yarn manufactured from thermoplastic fiber enables the ratio of resin/reinforcing fiber in the fabric to be adjusted easily. The present invention comprises application of 0-100 bars, preferably in range of 0-40, of pressure on the resin in step of heating of the resin.

In the present invention, the cooling of the resin penetrating into the fabric is carried out under 0-100 bars of pressure, preferably in range of 1-40 bars of pressure.

In the said invention, the weight of the thermoplastic resin used for stabilization is maximum 10% of the weight of the yarn manufactured from reinforcing fiber.

In the production method used for stabilizing the textiles comprising reinforcing fiber, discontinuous or continuous methods can be used. The main principle used in both methods is to apply the resin used for stabilizing the non-crimp fabric produced with yarn manufactured from reinforcing yarn in thermoplastic yarn form, and to apply pressure (0-100 bar) at a temperature above softening or melting point, and to enable the resin to impregnate into the reinforcing yarns in this way. Cooling process is applied after temperature and pressure is applied for a determined time between 0.01 minutes and 60 minutes. Cooling process can be applied without pressure or under pressure (0-100 bar) depending on the structure of the polymer. The cooling temperature is below the glass transition temperature (T g ) of the resin. The temperature range that can be used in cooling process is between 25°C and 200°C. The applications known in the state of the art cannot provide the resin to be homogenously impregnated into the fibers and cannot provide precise resin distribution. On the other hand, in the inventive method, since the resin is used in yarn form, the resin/reinforcing fiber ratio can be accurately adjusted. In summary, with the newly developed method, resin homogenization in amount is provided before starting the process.

In another preferred embodiment of the invention, the yarns manufactured from reinforcing fiber (glass, carbon, aramid, natural fiber, etc.) used in dry fabric are applied in single layer or different layers of the fabric, and thus it is possible to use the hybrid structure obtained in this way. Two or more types of reinforcing yarns (A) can be used in hybrid fabrics. For example, carbon (A), glass (A) and thermoplastic yarn (B) can be used in the same non-crimp fabric. Within the scope of the inventive method, dry fabric comprising reinforcing yarn (A) and thermoplastic yarn (B) is produced with weaving machine. During production, stabilized textile material can be produced in the same process by using infrared heater right after the weaving process. Therefore, there is no extra process step required during powder or liquid coating applied for conventional thermoplastic stabilization production, and thus the production is carried out faster. By means of the said method, complex composite parts can easily be manufactured via easy lay-up.

In the inventive production method, non-crimp fabrics comprising reinforcing yarn (A) and thermoplastic yarn (B) can be processed in more accurate resin amounts, and they can be processed more easily.

By means of the fabric kinds that are designed differently, textiles with different mechanical properties can be obtained. By this means the composite structure can be varied compatible with the field of use of the end user. Furthermore, the inventive fabrics are suitable for being used in wide range of application fields since it allows placing the reinforcing yarn in different axes.