METHOD FOR MANUFACTURING A COMPOSITE ARTICLE AND COMPOSITE ARTICLE

Abstract: In a method for manufacturing a shaped composite article by dry impregnation a matrix material (6) in a solid state is combined with a reinforcing material and the matrix material is subjected to heat treatment for converting it to a material in the state of a continuous phase. The reinforcing material comprises at least one layer (5) of knitted web. The matrix material is of thermoplastic plastic material or of a carbonizable polymer, and it is brought in contact with the layer of knitted web in the form of fibres or powder before the heat treatment.

Description: Method for manufacturing a composite article and composite article The invention relates to a method for manufacturing of a composite article, as defined in the preamble of claim l, as well as to a composite article according to claim 11. A composite is defined as a combination of two or more materials. When two different substances are combined in the microscopical scale, a roacroscopically homogenous material, that is, a composite, is formed. The composite will often have the best properties of both components and it may also have quite new pro- perties. The composites show usually the following improved properties: - strength - rigidity - weight - external appearance - ther otechnical properties - heat conductance - heat insulation - fatigue durability - corrosion resistance - wear resistance - sound insulation Of course, all the above-mentioned points do not change at the same time. At the present, the composites have aroused interest very widely, because they are suitable for structures which are light and require great rigidity and strength. New composite materials have been developed mainly by the aircraft and space industry. The ther- mosetting plastics cross-linkable by heat, such as polyesters and epoxy resins have been conventionally matrices for the composites, but the situation is slowly changing with the development of new technical thermoplastic plastic materials having good physical properties. The properties of the composites are due mainly to continuous technical fibres, which have been on the market since the Second World War. The most important are carbon, aramid and glass fibres (in the order given) , and ceramic boron and silicon carbide and aluminium oxide can be given as examples of other interesting compounds. Conventional matrices for the structural composites are represented by thermally cross-linkable epoxy resins, polyesters, polyimides, phenols, . vinylesters and silicones. Relatively good thermotechnical properties, moderate chemical strength and dimensional stability are regarded as advantages of the thermosetting plastics. During the last decen- nium the composite technology based on thermosetting matrices has reached a level on which the sufficient performance of the articles is combined with quite an effective manufacturing technique. The brittleness, sensitivity to moisture and the slow chemical manufac¬ turing method connected with a short storage stability of the basic reagents has become a slowing factor and in some cases even a bar for the future development of the composites made of thermosetting plastics. The present thermosetting matrices requiring a slow cross- linking reaction make the manufacturing times longer and restrict the design and treatment of the article, thus raising the processing expenses. The use of thermoplastic plastic matrices in the composites will increase with the developing work of new technical polymers, such as polypropene (PP) , polyphenylenesulphide (PPS) , polyetheretherketone (PEEK) and polyethersulphone (PES) . Briefly, the following factors will contribute to the breakthrough of thermoplastic matrices: - greater rigidity, which is shown f.ex. by a better compression strength and resistance to the pro¬ pagation of crack between laminated plates after a hard impact, compared with thermosetting plastics - smaller sensitivity to moisture, that is, smaller hygroscopicity, - higher continuous temperatures in use (for some polymers) - better resistance to chemicals (for some polymers) greater compression strength in hot and moist conditions easily realizable physical thermoforming and/or pressure forming - thermoforming and/or pressure forming can be repeated several times, broken structures can be repaired easily - refuse pieces and waste from finishing are suitable as raw material for e.g. injection moulding - lower manufacturing costs, for example storage stability of thermoplastic granulates nearly infinite, no expensive cooling equipment needed - articles fabricated from different batches are of a more uniform guality - possibility to apply moulding techniques of metals Nowadays mainly the aircraft industry is shifting towards the use of thermoplastic plastic composites with continuous fibres, because they have a better durability in hot and moist conditions than have the thermosetting plastic composites. When thermoplastic plastics are used they serve usually as the matrix of the composite, in which event they either are extruded to a film or defibrated. Well-known techniques for manufacturing of thermoplastic composites are for example: - Alternate stacking of matrix films and reinforcing fibres by compression moulding (film stacking) - Hybrid fibres, yarns and fabrics (blend of rein¬ forcing and matrix fibers) - Powder impregnation Solution impregnation - Melt impregnation for example by crosshead die, pultrusion and winding. The viscosity of the thermoplastic plastics is high, thus resulting in difficulties to thoroughly wet various reinforcing fibres with them. In addition, the melt impregnation results in stiff plates which require very expensive compression moulds in their further processing to shaped articles. In the finished product some areas void of matrix and having uneven wall thicknesses may be produced in course of compres¬ sion. Further, the stiff technical reinforcing fibres may be damaged by buckling because of compression moulding, which makes the mechanical properties of the finished composite poorer. When hybrid fibres are used, they must be first formed to a yarn, whereafter they usually are woven and laminated and compressed by means of pressure and heat to an article. In the methods known heretofore the difficulty has been to find such a reinforcing material that would have good properties as regards strength, but which at the same time would be useful as regards the techni¬ cal methods. The object of the invention is to accomplish a dry impregnation method which can be particularly well used especially in such applications that require an easy shaping of the material combination before the thermal compression stage. For achieving said goal the method according to the invention is. mainly characterized by what is disclosed in. the character¬ izing portion of claim 1. The invention is based on the use of a knitted web as the structure that reinfor- ces the matrix. By the method according to the invention, composites of thermoplastic matrix can be manufactured continuous¬ ly by the present-day mass production methods at a high rate and with a reasonable price. By means of the method according to the invention the matrix can be also distributed very uniformly onto the rein¬ forcement. By means of the invention, articles having a very wide surface and geometric versatility can be manufactured. The dry-impregnated half-fabricate with a thermoplastic matrix (prepreg) is most preferably a flexible product, which is both well settled (drape- able) and easily and stably formed in difficult mould geometries, of which spherical articles can be men- tioned as one example. By means of heat and pressure said prepreg can be brought to a rigid plate-like shape, which can be shaped to an article by compression moulding. As the flexible half-fabricate is passed through a heating zone, it can be formed by means of a negative or positive pressure to a shaped article. The method according to the invention makes it thus possible to provide an integrated continuous manufac- turing line for articles having a wide surface and complicated geometry, the line comprising the feed of the raw-materials (matrix felt and/or fibres and/or particles and the knitted web) , prebonding to the knitted web, the heating and pressure zone as well as the finishing stages. In said manner for example various components of the inner and outer part of a car body can be manufactured at a high rate. In the most preferable case the flexible thermoplastic half- fabricate can be delivered to the end user, which brings it by means of heat and pressure to the final shape of the product. The method in question is not only limited to thermo¬ plastic plastics, but it can be also used for manufac- turing similar articles by carbonization, in which event the thermal " compression will be replaced by a stage in a chamber in a protective atmosphere. When for example phenol, viscose or polyacrylonitrile fibers are used as the matrix and the material for the knitted web is of ceramic, mineral or rock fibre the matrix can be carbonized resulting in carbon reinforced with knitted web. If for example phenol is used, amorphous carbon is obtained in the end. If the felt and the knitted web are both of a carbonizable material, a carbon/carbon composite is obtained in the carbonizing process, retaining the reinforcing component still in the form of a knitted web. The impact strength of said carbon components is higher than that of the materials without a reinforcement. By means of the dry impregnation method of the in¬ vention it is possible to produce reinforced thermo¬ plastic composites that are needed in for example cars, boats, aircraft as well as in the building and process industry. The composite article according to the invention is characterized by what is disclosed in the character¬ izing portion of claim 11. The continuous solid phase constituted of the matrix material contains a knitted web as the reinforcing material. The advantages of the articles reside, in addition to the advantages connected with their manufacture, in the versatility of shapes and good strength properties. The invention will be described more closely in the following with reference to the accompanying drawings, of which Fig. 1 shows in cross-section a part of a dimen- sionally stable shaped composite article manufactured by means of the method of the invention. Fig. 2 shows schematically the different stages of the method, Fig. 3 shows in cross-section the intermediate product obtained in the method, Fig. 4 shows the same intermediate product manufactured according to another alter- native of the method. Fig. 5 showsthe intermediateproductmanufactured according to a third alternative of the method, Fig. 6 shows the possibility to place layers of reinforcing material in the product, taken in cross-section perpendicularly to the plane of the intermediate product and in section parallel to the plane, respect¬ ively, Fig. 7 shows another alternative for the placement of layers of reinforcing material in the product, Fig. 8 shows a preferred embodiment of the layer of reinforcing material, and Fig. 9 shows a yarn type for the layer according to Fig. 8. Fig. 1 shows a part of a di ensionally stable shaped composite article manufactured by the method according to the invention. In the manner common to all com¬ posites, the article consists of matrix material 6 and a layer 5 of reinforcing material embedded at least partly in the matrix material. The matrix material 6 is in the final product in the form of a continuous phase without any macroscopic boundaries between the matrix material, contrary to for example the previous patent application no. 901745 by the Applicant, in which the matrix material comprises separate particles. Together with the layer of rein¬ forcing material the matrix accomplishes a certain dimensional stability of the article. In accordance with the invention the layer 5 of reinforcing material is a knitted web, which can be easily shaped and retains well its shape, which is of particularly use during the preceding manufacturing stages to be discussed in the following, and also as regards the final product. Fig. 2 shows schematically the main method stages. The method comprises the introducing of a matrix material 6 in a solid state as separate particles in contact with the knitted web 5 and bonding to the knitted web (points A and B) , whereafter a so-called prepreg half-fabricate is obtained, the method further comprising a heat treatment, in which the matrix material 6 being shaped before this into a desired shape by virtue of the deformability of the knitted web 5 is brought to a predetermined temperature in which the final shaping of the article takes place (point C) . The heat treatment can comprise a densifying moulding of the matrix material, that is, the material is melted by means of heat while it remains shaped in the desired shape by means of pressure, whereafter after the solidification of the material the article remains in its final shape having a smaller volume than the prepreg half-fabricate. The particles of the matrix material are in this case some suitable ther¬ moplastic material usable in densification moulding and well suitable for the manufacture of shaped articles in the dry impregnation process. The heat treatment can also consist of the carbonization of the matrix material, whereby the polymeric material is carbonized in a suitable protective atmosphere and will form carbon. In Figs. 3 and 4 are presented some intermediate products obtained after point B of Fig. 2. Fig. 3 illustrates a so-called sandwich-construction, in which the layer 5 of knitted web remains inside the material which has been fed on the opposite sides of the layer 5 of knitted web as two separate felt layers 6a and 6b. The felt layers 6a and 6b are secured to the layer 5 of knitted web by needling whereby the layers 6a and 6b are bonded also mutually by means of some fibres therein. The layers 6a and 6b can be made to form a sandwich-construction on the opposite sides of the layer 5 of knitted fabric also in such a manner that the layers are not fed in the state of a finished non-woven felt but in the state of a card mat. In this case they can be also needled to the layers 5 and to each other. Fig. 4 shows an alternative according to which the matrix fibres have been brought in a single felt layer or card mat 6 in contact with the layer 5 of knitted web, whereafter the needling has been carried out to allow the layer 6 of matrix material to pene- trate into the knitted web as well, that is, the layer 5 of knitted web does not remain on the surface of the material. It will be understood that the location of the layer 5 of knitted web relative to the outer surfaces of the matrix material layer 6 and at the same time the filling of the knitted web with the matrix material can be adjusted by adjusting the needling depth. In this way it is also possible to manufacture a composite article resembling that of Fig. 1, both the opposite outer surfaces being formed by the same matrix material and the knitted web remaining entirely inside the surfaces. All the constructions shown in Figs. 3-4 can be manufactured in the practice in conventional processing lines, whereon a matrix material layer 6 in the form of a continuous web or several such layers 6a, 6b and a layer or layers 5 of knitted web, which also are in the form of a continuous web, can be brought together (Fig. 2, point A) and secured to each other (Fig. 2, point B) . Fig. 5 illustrates an alternative for bringing the matrix material in contact with the knitted web 5, differing from the alternative of Figs. 3 and 4. The matrix material is in powder form and the powder particles 6c are brought in contact with the knitted web moving forward in the form of the continuous web at point A in Fig. 1. At point B, plastic films 6d are joined on both sides, one of the films being introduced to the advancing web from above and the other of the films is introduced from below for example through a space between two successive conveyor belts. Fig. 1 depicts this possibility by broken lines, and also reels 7 to deliver the films are shown in the same figure. Alternatively, the films can be formed by extrusion simultaneously on the same line and they can be introduced on the matrix and the knitted web. The films are preferably of the same material as the particles 6c of the matrix and they will be melted in a heat treatment (thermoplastic polymers) or will be carbonized (carbonizable polymers) , forming a con¬ tinuous phase. It will be understood that, in addition to particles 6c, the matrix material can also comprise fibrous matrix material being denoted by broken lines in Fig. 5. This can be brought in contact with the knitted web 5 either before the introducing of the powder, thereafter, or simultaneously with the powder. In the above cases also the needling can be carried out before the joining of the films 6d. The powder alternative is particularly well suitable when the purpose is to use thermoplastic urethane which in this way can be brought by dry impregnation in contact with the knitted web 5 acting as the reinforcement. By this method various articles having a good impact strength and an elastic structure can be manufactured, such as bellows, conveyor belts or fibration dampers. In said case both the particles 6c and the films 6d are of said material which melts in course of the heat treatment, forming the continuous matrix phase. A final product containing many reinforcing layers can be manufactured by stacking separate layers comprising the reinforcing layer 5 onto each other before the heat treatment to form the final product. In the treatment the layers are laminated together. Fig. 6 shows an intermediate product according to a third alternative, according to which the reinforcing material comprises, in addition to the layer 5 of knitted web, also parallel reinforcing elements 5 1 to give additional strength to the final product in the direction of the reinforcing elements, if desired. Some continuous filament fibre can be used as the rein¬ forcing elements and it will, as apparent from Fig.- 5a, be also situated inside the matrix material layer 6 constituted of fibres. These elements can be intro¬ duced into the matrix material on the line of Fig. 2 at point A as well, for example by feeding the parallel reinforcing elements and the knitted web one above each other before the bringing of the matrix material in contact therewith, or a layer of matrix material will remain therebetween. Fig. 7 shows further schema¬ tically an alternative according to which the product comprises two layers 5a and 5b of knitted web, in which the wales extend crosswise to give more uniform strength properties in the direction of the plane of the reinforcement. This can be accomplished by intro¬ ducing the knitted webs on top of each other as early as at the point A or at a later stage by stacking the layers containing the knitted webs just before the heat treatment. Any thermoplastic plastic particles shapeable by means of heat and pressure can be used as the matrix material. The particles can be fibrous, resulting in an intermediate product in the form of felt which yet in the ultimate treatment converts to entirely con¬ tinuous matrix, contrary to the felt disclosed in the previous patent application no. 901745 by the Applicant where the felt retains its felt-like texture also in the state where it is impregnated with a thermosetting plastic material. As described above, powdery thermo- plastic particles can be also introduced to the knitted web at point A. The retention of the particles with the knitted web can be ensured instead of needling by enclosing the knitted web and the powdery particles inside the thermoplastic plastic films passed onto both sides. The thermoplastic films are in this case of the same material as the powder particles and the films can be fixed by thermal bonding onto both sides of the matrix. As mentioned hereinbefore, carbonizable polymers are also suitable for a matrix material either in a fibrous or powdery state, making the pretreatment possible on the same principles as described above. In addition to the actual matrix material, additives well-known in the plastics and composite technology can be used in the matrix. A yarn having a continuous mono- or multifilament, such as glass fibre, plastic such as polyester, or metal or ceramic material, is preferably used as the raw material for the layer 5 of knitted web. The yarn formed of the filaments is preferably textured, in which case the loops of the knit will be better filled in the dry impregnation step. Fig. 8 shows also a knit structure which is particularly well suitable for the dry impregnation method in accordance with the invention. The attachment of the particles of the matrix material to the layer 5 of knitted web has been improved by forming the knit from a yarn having fibres 3 extending sideways and filling the void loops 4 of said knit. By this provision, the knitted web will have a strong structure in the direction of its plane and, in addition to that, the fibres 3 contribute to the better impregnation of the knitted web with the particles of the layer 6 of matrix material, resulting in a stronger bond between the reinforcing material and the matrix when forming the product to the final dimensionally stable product. For example when fibres are used as the matrix material they can be attached to the fibres 3 of the layer of knitted web upon penetrating in course on needling inside the loops 4. The bonding of the matrix material layer will be improved and the processing of the intermediate product will be facilitated. For obtaining the fibres 3 which fill the inside of the knit loops of Fig. 8 the knitted web is manu- factured of a yarn shown in Fig. 9. The yarn comprises a yarn 1 in the form of a continuous filament which forms the part of the yarn receiving the tensile stress. Said yarn can be a monofilament or a multi- filament and it can be for example of glass fibre or any other filament fibre well resistant to tensile stress. The yarn 2 consisting of staple fibres is wound around the core yarn 1 and has fibres 3 with their ends twisted sideways away from the running direction of the yarn. The staple fibres are most preferably stiff technical fibres such as glass fibres, ceramic fibres or some other inorganic fibres, carbon fibres, or synthetic polymer fibres, such as ara id fibres. Owing to the stiffness of the fibres the ends of the fibres are caused to spread out in a straight condition sideways when the yarn is wound. Another alternative for the yarn of the knitted web is a hybrid yarn formed solely from staple fibres by spinning, containing reinforcing fibres retaining their form of the knitted web in the final product, and further containing matrix fibers of thermoplastic plastic material which melt in the heat treatment together with the actual matrix material. One example of this provision is the yarn manufactured in the so- called Heltra process. In this yarn the carbon fibres serve as reinforcing fibres and PEEK (polyetherether- ketone) serves as the matrix fibers. The matrix fibers of the yarn and the actual matrix material are prefe¬ rably of the same polymer. In the invention, any type of knit can be used as the knitted web forming the knit layer 5, such as for example flat stitch knit, interlock stitch knit etc. , according to the desired shaping behaviour and strengthening effect. The selection of knit type can be used in adjusting the macroscopic deformation degree of the prepreg and final product. The knitted web is particularly useful in the sense that the degree of the deformation is not dependent on the stretching capacity of the yarn in the reinforcement, but on the macroscopic structure of the knitted web. Even if a continuous manufacturing line is shown in Fig. 2, starting from the raw material and ending in a finished shaped article, the relatively flexible intermediate product, the so-called prepreg material obtainable after points A and B, can be stored and transported to a totally different place where the final manufacturing of the product takes place (point C). It is self-evident that the proportions of the matrix material and reinforcement in the total weight of the product can vary within a suitable range. The propor¬ tion of the reinforcement in the final product is most preferably more than 50%, and the ratio of 30% matrix and 70% reinforcement can be regarded as a good guideline value. The invention is not restricted above only to an embodiment presented in the description or in the Figures, but it can be varied within the scope of the invention presented by the claims. The matrix material is most preferably of the same polymer, but a blend of two or several polymers is also conceivable, the blend forming the continuous phase in the final product, provided that the properties of the polymers are compatible with each other.

Claims: Claims 1. Method for manufacturing a shaped composite article by dry impregnation, which comprises the combining of a matrix material in a solid state with a reinforcing material and subjecting the matrix material to a heat treatment to convert it to a material in the form a continuous phase, characterized in that the reinforcing material comprises at least one layer (5) of knitted web. 2. Method as claimed in claim 1, characterized in that the matrix material is brought as fibres in contact with the layer (5) of knitted web, whereafter the matrix is subjected to treatment for converting it. 3. Method as claimed in claim 2, characterized in that the matrix fibres are brought as separate layers (6a, 6b) on both sides of the layer (5) of knitted web before the treatment of the matrix. 4. Method as claimed in claim 3, characterized in that the layers (6a, 6b) are bonded to the layer (5) of knitted web by needling. 5. Method as claimed in claim 2, characterized in that the matrix fibres are brought on one side in contact with the layer (5) of knitted web, whereafter they are bonded by needling in such a fashion that the layer (5) of knitted web will remain inside the layer (6) constituted of the matrix fibres before the treatment of the matrix. 6. Method as claimed in claim 1, characterized in that the matrix material comprises powder (6c) which is brought in contact with the layer (5) of knitted web, whereafter optionally a film (6d) is introduced at least on one of the surfaces of the matrix layer. 7. Method as claimed in any of the preceding claims, characterized in that in addition to the knit of the layer (5) of knitted web, reinforcing elements (5*) extending mainly in one direction are brought in contact with the matrix material. 8. Method as claimed in any of the preceding claims, characterized in that the matrix material is of thermoplastic plastic material and the heat treatment for changing the state of the matrix material comprises- melting, shaping and solidification of the matrix material by means of heat and pressure. 9. Method as claimed in any of claims 1-7, charac¬ terized in that at least the matrix material is of a carbonizable polymer, such as phenol, viscose or polyacrylonitriϊe fibres or powder, the changing of the matrix material comprising the carbonization of the polymer in a suitable environment to form carbon. 10. Method as claimed in any of the preceding claims, characterized in that the layer (5) of knitted web comprises fibres (3) directed sideways from the yarn (1, 2) constituting the knitted web, the particles (6) of the matrix material, such as the fibres, being attached to said fibres before the treatment of the matrix. 11. Composite article comprising a continuous phase obtained by heat treatment of a matrix material in a solid state and further comprising a reinforcing material in said continuous phase, characterized in that the reinforcing material comprises at least one layer of knitted web. 12. Composite article as claimed in claim 11, char¬ acterized in that in addition to the knit of the layer (5) of knitted web, the matrix material comprises reinforcing elements (5 1 ) extending mainly in one direction. 13. Composite article as claimed in claim 12, charac¬ terized in that the reinforcing elements (5') extending in one direction run in such a fashion that their main direction is substantially perpen¬ dicular to the direction of the wales of the knit of the layer of knitted web. 14. Composite article as claimed in any of the preceding claims 11-13, characterized in that the reinforcing material comprises layers (5a, 5b) of knitted web in which the wales run crosswise. 15. Composite article as claimed in any of the preceding claims 11-14, characterized in that in order to strengthen the layer of knitted web in the direction of its plane and in order to improve the bond between the matrix and the layer of knitted web, the yarn forming the knit of the layer of knitted web has fibres (3) extending sideways therefrom and filling the loops of the knitted web.

Inventors: KARTTUNEN MIKKO, SUOKAS ESA, KARTTUNEN, MIKKO, SUOKAS, ESA
Applicants: VALTION TEKNILLINEN, VALTION TEKNILLINEN TUTKIMUSKESKUS
Application year: 1991
Main classification: B32B27
IPC codes: B29B11, B29B15, B29K105, B32B27, C04B35, D06N3