The present invention concerns a reinforcing material comprising at least one fibrous reinforcement associated on at least one of its faces with a thermoplastic porous layer, said thermoplastic porous layer(s) representing at most 10% of the total mass of the reinforcing material, preferably from 0.5 to 10% of the total mass of the reinforcing material, and more preferably from 2 to 6% of the total mass of the reinforcing material, characterized in that said thermoplastic porous layer or each of said thermoplastic porous layers present comprises a so-called reactive thermoplastic polymer or consists of one or more reactive thermoplastic polymers, a reactive thermoplastic polymer carrying —NH2 functions in an amount greater than 0.15 meq/g of reactive thermoplastic polymer and/or carrying —COOH functions in an amount greater than 0.20 meq/g of reactive thermoplastic polymer.
The present invention concerns a reinforcing material comprising at least one fibrous reinforcement associated on at least one of its faces with a thermoplastic porous layer, said thermoplastic porous layer(s) representing at most 10% of the total mass of the reinforcing material, preferably from 0.5 to 10% of the total mass of the reinforcing material, and more preferably from 2 to 6% of the total mass of the reinforcing material, characterized in that said thermoplastic porous layer or each of said thermoplastic porous layers present comprises a so-called reactive thermoplastic polymer or consists of one or more reactive thermoplastic polymers, a reactive thermoplastic polymer carrying —NH2 functions in an amount greater than 0.15 meq/g of reactive thermoplastic polymer and/or carrying —COOH functions in an amount greater than 0.20 meq/g of reactive thermoplastic polymer.
The invention also concerns processes for manufacturing such reinforcement materials, preforms, processes for manufacturing composite parts and composite parts using such reinforcement materials.
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 3/08 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by added members at particular parts
B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
C08J 5/24 - Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
D04H 3/16 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
2.
REINFORCING MATERIAL COMPRISING TWISTED CARBON THREADS FOR THE MANUFACTURE OF COMPOSITE PARTS, AND CORRESPONDING METHODS AND USE
The invention relates to a reinforcing material (1) consisting of a unidirectional reinforcing web (2) formed of one or more carbon reinforcing yarns (3), associated on each of its faces with a veil of polymeric fibers (4, 5) chosen from among nonwoven materials, the polymeric portion of the reinforcing material representing from 0.5% to 10% of the total weight of the reinforcing material (1), and preferably from 2% to 6% of its total weight, said unidirectional reinforcing web (2) comprising one or a series of reinforcing yarns (3) individually twisted having a twist of 3 turns/m to 15 turns/m, preferably from 6 turns/m to 12 turns/m.
D02G 3/26 - Yarns or threads characterised by constructional features with characteristics dependent on the amount or direction of twist
B29C 70/20 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in a single direction, e.g. roving or other parallel fibres
B29K 105/10 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns oriented
B32B 5/12 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by the relative arrangement of fibres or filaments of adjacent layers
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
D04H 3/04 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
3.
NEW REINFORCING MATERIALS BASED ON S- AND Z-TWISTED YARNS FOR THE MANUFACTURE OF COMPOSITE PARTS, METHODS AND USE
The reinforcing material comprises a unidirectional reinforcing web (2) formed of one or a plurality of carbon yarns (3), associated on at least one of its faces, preferably on each of its faces, with a porous polymeric layer (4, 5), the polymeric portion of the reinforcing material representing from 0.5% to 10% of its total weight and preferably from 2% to 6% of its total weight, characterized in that said carbon yarns (3) are individually twisted having a twist from 3 turns/m to 15 turns/m, preferably from 6 turns/m to 12 turns/m, and comprise at least one S-twist yarn and at least one Z-twist yarn, from a selection according to claim 1.
B29C 70/20 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in a single direction, e.g. roving or other parallel fibres
B29C 70/08 - Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, with or without non-reinforced layers
B29C 70/38 - Automated lay-up, e.g. using robots, laying filaments according to predetermined patterns
B32B 3/18 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material characterised by an internal layer formed of separate pieces of material
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
D02G 3/02 - Yarns or threads characterised by the material or by the materials from which they are made
D02G 3/26 - Yarns or threads characterised by constructional features with characteristics dependent on the amount or direction of twist
D02G 3/44 - Yarns or threads characterised by the purpose for which they are designed
The present invention relates to a reinforcement material including at least one fiber reinforcement associated on at least one of its faces with a porous layer, the porous layer(s) representing no more than 10% of the total weight of the reinforcement material, preferably from 0.5 to 10% of the total weight of the reinforcement material, and most preferably from 2 to 6% of the total weight of the reinforcement material, characterized in that the porous layer contains a partially cross-linked thermoplastic polymer. Another object of the invention is a precursor material of such a reinforcement material, as well as their preparation method and the methods for manufacturing a preform or a composite part from such materials.
The present invention relates to a reinforcement material including at least one fiber reinforcement associated on at least one of its faces with a porous layer, the porous layer(s) representing no more than 10% of the total weight of the reinforcement material, preferably from 0.5 to 10% of the total weight of the reinforcement material, and most preferably from 2 to 6% of the total weight of the reinforcement material, characterized in that the porous layer contains a partially cross-linked thermoplastic polymer. Another object of the invention is a precursor material of such a reinforcement material, as well as their preparation method and the methods for manufacturing a preform or a composite part from such materials.
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 7/09 - Interconnection of layers by mechanical means by stitching, needling or sewing
B32B 3/10 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
The present invention relates to a reinforcement material including at least one fiber reinforcement associated on at least one of its faces with a porous layer, the porous layer(s) representing no more than 10% of the total weight of the reinforcement material, preferably from 0.5 to 10% of the total weight of the reinforcement material, and most preferably from 2 to 6% of the total weight of the reinforcement material, characterized in that the porous layer contains a partially cross-linked thermoplastic polymer. Another object of the invention is a precursor material of such a reinforcement material, as well as their preparation method and the methods for manufacturing a preform or a composite part from such materials.
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 7/09 - Interconnection of layers by mechanical means by stitching, needling or sewing
B32B 3/10 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form characterised by a discontinuous layer, i.e. apertured or formed of separate pieces of material
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 7/12 - Interconnection of layers using interposed adhesives or interposed materials with bonding properties
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
The invention relates to a blank for compression moulding a part in a compression mould comprising one or more moulding recesses, said blank comprising a body formed from a first moulding compound comprising a fibrous reinforcement material and a thermo-curable resin material, and a region located on the surface of the body formed from a second moulding compound; said second moulding compound comprising a fibrous reinforcement material and a thermo-curable resin material, and exhibiting increased flow at one or more temperatures between 20° C. and the cured Tg of the first moulding compound compared to the flow of the first moulding compound at the same temperature.
B29C 43/00 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor
B29C 43/02 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
C08J 5/24 - Impregnating materials with prepolymers which can be polymerised in situ, e.g. manufacture of prepregs
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B29C 70/08 - Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, with or without non-reinforced layers
B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
B29K 105/00 - Condition, form or state of moulded material
8.
IMPROVEMENTS IN OR RELATING TO THREE DIMENSIONAL MOULDINGS
The invention relates to a blank for compression moulding a part in a compression mould comprising one or more moulding recesses, said blank comprising a body formed from a first moulding compound comprising a fibrous reinforcement material and a thermo-curable resin material, and a region located on the surface of the body formed from a second moulding compound; said second moulding compound comprising a fibrous reinforcement material and a thermo-curable resin material, and exhibiting increased flow at one or more temperatures between 20°C and the cured Tg of the first moulding compound compared to the flow of the first moulding compound at the same temperature.
B29C 43/02 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
B29K 105/00 - Condition, form or state of moulded material
B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
9.
IMPROVEMENTS IN OR RELATING TO THREE DIMENSIONAL MOULDINGS
This invention relates to a moulding compound blank, a method for compression moulding the same and the resulting product. The blank comprisies a moulding compound comprising a fibrous reinforcement material and a resin material wherein the moulding compound comprises a flow guide (6, 7, 8) located at the surface of the blank for directing flow of the moulding compound within the cavity of the compression mould during compression moulding.
B29C 43/02 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles
B29K 105/00 - Condition, form or state of moulded material
B29K 105/08 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
B29K 105/12 - Condition, form or state of moulded material containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
B29C 33/42 - Moulds or coresDetails thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
10.
SUPPORT MATERIAL, SHEET MOULDING COMPOUND AND PROCESS FOR MAKING A MOULDING MATERIAL
A process of forming a moulding material is provided, moulding process comprising: a) providing a substrate material; b) providing a support material comprising a moulding material comprising a resin material conjoined to the surface of a fibrous reinforcement material or a moulding material comprising a resin material at least partially impregnating a fibrous reinforcement material; c) locating said substrate material and said moulding material in relation to a mould; and d) forming the substrate and curing said moulding material to bond the moulding material to the substrate, the bonding is provided by step where an adhesive layer is applied between the support material and the substrate material, the adhesive layer extending beyond the moulding material.. The substrate material and the support material are provided in the form of a sheet moulding compound comprising a substrate material having conjoined thereto a moulding material comprising- a resin material conjoined to the surface of the fibrous reinforcement material, the method further comprising: a) locating the sheet moulding compound in a mould; and, b) forming the substrate and curing the resin material. Also, it 'is afforded a use of a support material to reinforce a formable material.
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 27/04 - Layered products essentially comprising synthetic resin as impregnant, bonding, or embedding substance
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B29C 35/02 - Heating or curing, e.g. crosslinking or vulcanising
B29C 43/30 - Making multilayered or multicoloured articles
B32B 37/12 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
patents
