• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
  • 引用文献
  • 法律状态
  • 优先权
    • 专利摘要:
    Composite panel and procedure for obtaining it. This composite panel (2), in particular, a composite laminated panel, comprises a first composite layer (4) comprising fibers of a first type of fibers (14), a second composite layer (6) comprising fibers of a second type of fibers (20), a third composite layer (8) comprising fibers of a third type of fibers (30). The first type of fibers are carbon fibers, the second type of fibers are natural fibers, the first composite layer comprises a first thermoplastic binder material (16), the second composite layer comprises a second thermoplastic binder material (22), the third layer The composite comprises a third thermoplastic binder material (32), and the third type of fibers are natural fibers with an average length greater than the average length of the second type of fibers. Application to automotive carrier panels. (Machine-translation by Google Translate, not legally binding)
    公开号:ES2736079A2
    申请号:ES201930463
    申请日:2019-05-27
    公开日:2019-12-23
    发明作者:Benjamin Quesnel；Garcia Carreno Xavier Toneu
    申请人:Faurecia Innenraum Systeme GmbH；
    IPC主号:
    专利说明:

    [0001]
    [0002] Composite Panel and Procedure for obtaining
    [0003]
    [0004] The present invention relates to a composite panel, in particular a composite laminated panel, comprising
    [0005] a first composite layer comprising fibers of a first type of fibers, a second composite layer comprising fibers of a second type of fibers, and a third composite layer comprising fibers of a third type of fibers.
    [0006]
    [0007] Background of the invention
    [0008]
    [0009] WO 2017/23764 describes a composite structure comprising three layers in which at least two of the layers comprise a different fiber material or a different fiber content.
    [0010]
    [0011] Additional multilayer structures are described, for example, in EP 2750879, EP 2842727 and WO 2017/112632.
    [0012]
    [0013] Description of the invention
    [0014]
    [0015] The known structures do not provide complete satisfaction and the objective of the present invention is to provide a composite panel that is relatively light, rigid and economical to manufacture. The composite panel according to the invention should preferably be ecological and use few resources.
    [0016]
    [0017] The composite panel must be widely used in industry, particularly in the automotive industry, for example, for door panels.
    [0018]
    [0019] In order to achieve at least one of the foregoing objects, the invention proposes a composite panel as defined above, characterized in that
    [0020] - the first type of fibers are carbon fibers,
    [0021] - the second type of fibers are natural fibers,
    [0022] - the first composite layer comprises a first thermoplastic binder material,
    [0023] - the second composite layer comprises a second thermoplastic binder material,
    [0024] - the third composite layer comprises a third thermoplastic binder material, and because the third type of fibers are natural fibers with an average length greater than the average length of the second type of fibers.
    [0025]
    [0026] According to specific embodiments, the composite panel according to the invention may comprise one or more of the following characteristics, taken alone or together in all possible technical combinations:
    [0027] - the first composite layer does not comprise natural fibers and the second composite layer does not comprise carbon fibers;
    [0028] - the fibers of the third type of fibers represent between 40% and 55% by weight of the third composite layer;
    [0029] - the third thermoplastic binder material represents between 35% and 50% by weight of the third composite layer;
    [0030] the fibers of the third type of fibers and the third thermoplastic binder material together represent 85% to 100% by weight of the third composite layer;
    [0031] - the third composite layer comprises an additional thermoplastic binder material which amounts to up to 15% by weight of the third composite layer, in particular the fibers of the third type of fibers, the third thermoplastic binder material and the additional amount of thermoplastic binder material amount to 100% by weight of the third composite layer;
    [0032] - the additional thermoplastic binder material is different from the third thermoplastic binder material, in particular, the third thermoplastic binder material being polypropylene (PP) and the additional thermoplastic binder material being a polyester, such as PET;
    [0033] - the first, third and / or additional thermoplastic binder material is in the form of fibers before laminating the first, second and third composite layer,
    [0034] - the first and second thermoplastic binder materials comprise polypropylene (PP), and in particular consist of polypropylene, and
    [0035] - the first type of fibers are recycled fibers and / or the second type of fibers are recycled fibers.
    [0036]
    [0037] The invention also relates to a process for obtaining a composite panel as defined above, the process comprising the steps of:
    [0038] - provide a precursor of the first composite layer,
    [0039] - provide a precursor of the second composite layer,
    [0040] - provide a precursor of the third composite layer,
    [0041] - superimposing the precursors of the first, second and third layers composed one on top of the other, such that the precursor of the second composite layer is positioned between the precursor of the first composite layer and the precursor of the third composite layer,
    [0042] - laminating the precursors of the first, second and third composite layers with respect to each other by heating the composite layers above the melting point of at least one of the thermoplastic binder materials, and
    [0043] - cooling the heated precursors of the first, second and third composite layers.
    [0044]
    [0045] According to one embodiment of the process, the precursor of the second composite layer comprises a recycled composite material comprising natural fibers and a thermoplastic binder material.
    [0046]
    [0047] Within the scope of this patent application, the various aspects, embodiments, examples, features and alternatives set forth in the preceding paragraphs, in the claims and / or in the following description and drawings may be taken independently or in any combination thereof. . For example, the features described in relation to one embodiment are applicable to all embodiments, except when there is technical incompatibility of the features. In addition, for any combination of features described, it is contemplated that the features can also be isolated and used individually or as any possible subset of the combination of features.
    [0048]
    [0049] Brief description of the figures
    [0050]
    [0051] The invention will be better understood in light of the following specification, which refers to the attached figures showing:
    [0052] - Figure 1 is a schematic view of a cross section of a composite panel according to a first embodiment of the invention;
    [0053] - Figure 2 is a schematic view of a cross section of a composite panel according to a second embodiment of the invention;
    [0054] - Figure 3 is a schematic view of an installation used to produce a component of a composite panel according to the invention, and
    [0055] - Figure 4 is a schematic view of an installation for producing a composite panel according to the invention.
    [0056]
    [0057] Description of a preferred embodiment
    [0058]
    [0059] Figure 1 shows in cross section a composite panel according to a first embodiment of the present invention, designated by general reference 2.
    [0060]
    [0061] The composite panel 2 is, in particular, a composite laminated panel.
    [0062]
    [0063] The composite panel 2 comprises a first composite layer 4, also called upper layer, a second composite layer 6, also called intermediate layer and a third composite layer 8, also called lower layer. The composite panel 2 comprises a first surface 10 and a second surface 12. The first surface 10 is formed in the present embodiment by the first composite layer 4 and may be what is generally called a "surface in A", which means that The first surface 10 may be a visible surface during the use of the panel. In some embodiments, the first surface may be covered by a decorative layer that forms the visible surface of the panel.
    [0064]
    [0065] The first composite layer 4 is attached to the second composite layer 6, which in turn is attached to the third composite layer 8, such that the second composite layer 6 is disposed between the first composite layer 4 and the third composite layer 8 The first composite layer 4 comprises fibers of a first type of fibers 14 and a first thermoplastic binder material 16. The first thermoplastic binder material 16 is advantageously in the form of fibers, in particular in the form of fibers before laminating the first, second and third layer Before laminating it means that the layers are manufactured by using thermoplastic fibers that will melt or partially melt during the manufacturing of the layers or at a later stage in the lamination process that results in the composite panel. The first thermoplastic binder material 16 may comprise polypropylene (PP) and may in particular consist of polypropylene. The text "consists of polypropylene" does not exclude that polypropylene comprises additives that are common for commercially available polypropylene, such as, for example, processing agents and pigments. These possible additives are only present in traces, such as, at most 5% by weight of the polypropylene material. According to a variant, the first thermoplastic binder material 16 may comprise or may consist of another thermoplastic material, such as another polyolefin. The first composite layer 4 is not woven and can be a fleece fabric.
    [0066]
    [0067] In the present embodiment, the first composite layer 4 consists of fibers of the first type of fibers 14 and the first thermoplastic binder material 16.
    [0068]
    [0069] Preferably, the first type of fibers 14 are recycled fibers. According to the invention, the first type of fibers are carbon fibers. More specifically, the composite panel 2 therefore comprises, in the first composite layer, 4 recycled carbon fibers. Therefore, composite panel 2 is particularly economical. The recycled carbon fibers can be carbon fibers from which a sizing has been removed and, therefore, are devoid of sizing. However, in general, the carbon fibers may be oriented, nonwoven or unidirectional oriented fibers.
    [0070]
    [0071] The fibers of the first type of fibers 14 in the first composite layer 4 can amount to up to 90% by weight, but advantageously amount to between 40 and 60% by weight of the first composite layer 4 and the first thermoplastic binder material 16 advantageously between 40 and 60% by weight of the first composite layer 4.
    [0072]
    [0073] The first composite layer 4 may also comprise an optional bonding agent (not shown) that is adapted to increase the adhesion of the fibers of the first type of fibers 14 to the first thermoplastic binder material 16. Therefore, optionally, the first composite layer 4 consists of fibers of the first type of fibers 14, of the first thermoplastic binder material 16 and of the optional bonding agent. The bonding agent is, for example, a maleic anhydride and, in particular, is grafted onto the first thermoplastic binder material 16 or otherwise added to or to the binder.] In particular, the first thermoplastic binder material 16 in the form of Fibers has the bonding agent grafted onto the surface of these fibers. Preferably, the bonding agent is grafted into the binder material before the binder material is cut into fibers.
    [0074] The carbon fibers of the first composite layer 4 have, for example, a length between 10 mm and 200 mm, more preferably between 40 mm and 120 mm, and a diameter between 3 micrometers and 25 micrometers, preferably between 5 micrometers and 15 micrometers
    [0075]
    [0076] The surface weight of the first composite layer 4 is between 75 and 125 grams / m2, for example, 100 grams / m2. The first composite layer 4 may have a thickness between 0.05 mm and 1.0 mm, preferably between 0.1 mm and 0.6 mm.
    [0077]
    [0078] The second composite layer 6 comprises fibers of a second type of fibers 20 and a second thermoplastic binder material 22. The second thermoplastic binder material 22 may comprise the same polymeric material as the first thermoplastic binder material 16.
    [0079]
    [0080] Advantageously, the second thermoplastic binder material 22 is recycled material. The second thermoplastic binder material 22 comprises polypropylene (PP) and, in particular, consists of polypropylene. Alternatively, the second thermoplastic binder material may comprise or consist of another thermoplastic material, for example, another polyolefin. The second composite layer 6 comprises short fibers.
    [0081]
    [0082] The second type of fibers are natural fibers. Natural fibers are, for example, bast fibers such as hemp, flax, kenaf or jute. Natural fibers can also be wood fibers, preferably softwood fibers such as coniferous fibers.
    [0083]
    [0084] The surface weight of the second composite layer 6 is, for example, between 400 and 900 grams / m2. Preferably, the surface weight of the second composite layer 6 is between 500 and 800 grams / m2, for example 600 grams / m2. The second composite layer 6 may have a thickness between 0.4 mm and 4.0 mm, preferably a thickness between 0.6 mm and 3.0 mm.
    [0085]
    [0086] The second composite layer 6 advantageously consists of the fibers of the second type of fibers 20 and the second thermoplastic binder material 22. Furthermore, advantageously, the second type of fibers are recycled fibers. More advantageously, the second composite layer 6 may comprise recycled composite material, for example, material crushed compound. In particular, an advantage for the recycled composite material is the waste material from the production of natural fiber composite panels. The granules of said recycled composite material typically have dimensions between 0.1 mm and 3 mm. As a consequence, the length of the fibers in the recycled materials typically amounts between 0.1 mm and 3 mm. The average length of the fibers of the second type of fibers 20 is between 0.05 mm and 4.0 mm.
    [0087]
    [0088] The third composite layer 8 comprises fibers of a third type of fibers 30 and a third thermoplastic binder material 32.
    [0089]
    [0090] The fibers of the third type of fibers 30 are natural fibers and represent between 40% and 55% by weight of the third composite layer 8. Natural fibers are, for example, bast fibers such as hemp, flax, kenaf or jute. Libero fibers typically have a beam diameter between 25 micrometers and 200 micrometers, preferably between 50 and 100 micrometers. The length of the bundles of bast fibers is typically between 30 mm and 150 mm, preferably between 40 mm and 120 mm. Natural fibers can also be wood fibers, preferably softwood fibers such as coniferous fibers. Typically, the diameter of the wood fibers is between 25 micrometers and 300 micrometers, preferably between 50 micrometers and 200 micrometers. The length of the wood fibers is typically between 5 mm and 15 mm, preferably between 9 mm and 12 mm. An average length of the third type of fibers is typically greater than 5 mm, and in some embodiments greater than 10 mm. A difference between the natural fibers of the second type of fibers and the natural fibers of the third type of fibers is that the recycled fibers in the second compound are shorter than the virgin fibers in the third layer. Then, even if the natural fibers in the second composite layer are of a similar origin and have a similar chemical composition, their length will be shorter due to the recycling process.
    [0091]
    [0092] The surface weight of the third composite layer 8 is, for example, between 400 and 900 grams / m2. Preferably, the surface weight of the second composite layer 8 is between 500 and 800 grams / m2, for example 600 grams / m2. The third thermoplastic binder material 32 amounts to between 35 and 50% by weight of the third composite layer 8. The fibers of the third type of fibers 30 and the third thermoplastic binder material 32 amount together from 85 to 100% by weight of the third composite layer 8. Any of the first, second or third binder materials Thermoplastics may comprise additives, for example, to improve processing and / or aging behavior. Any, several, or each of the first, second and third thermoplastic binder materials may comprise additives such as a processing agent or agents, colorants or pigments and / or adhesion promoters for the fibers of the respective layer.
    [0093]
    [0094] The third composite layer 8 may comprise an additional thermoplastic binder material, which amounts to up to 15% by weight of the third composite layer. In particular, the additional thermoplastic binder material amounts to 1% and more by weight of the third composite layer 8 and in particular comprises between 8 and 12% by weight of the third composite layer. Advantageously, the fibers of the third type of fibers 30, the third thermoplastic binder material 32 and the additional thermoplastic binder material 34 together amount to 100% by weight of the third composite layer 8. In other words, the third composite layer 8 is composed exclusively by, or consists of, the fibers of the third type of fibers, the third thermoplastic binder material and the other thermoplastic binder material 34.
    [0095]
    [0096] The natural fibers of the third type of fibers 30 are selected, for example, from the same types of fibers as the second type of fibers. Typically, the length of the natural fibers is between 30 mm and 150 mm for the bast fibers and between 5 mm and 15 mm, preferably between 9 mm and 12 mm for the wood fibers. The length of these natural fibers is greater than the length of the fibers in the second composite layer 6. More precisely, the second type of fibers 20 are fibers with an average length less than the average length of the third type of fibers 30.
    [0097]
    [0098] Advantageously, the natural fibers of the third type of fibers 30 are, apart from their length, identical to the natural fibers of the second type of fibers 20. In one embodiment, the third composite layer is made of virgin material, while the second layer is Made of similar or the same material, but a recycled material.
    [0099]
    [0100] The additional thermoplastic binder material 34 is different from the third thermoplastic binder material and is, in particular, a polyester and advantageously polyethylene terephthalate (PET). The third thermoplastic binder material can be polypropylene.
    [0101] The third and / or additional thermoplastic binder material 32, 34 may be in the form of fibers, in particular before rolling.
    [0102]
    [0103] The surface weight of the third composite layer 8 is, for example, between 100 and 600 grams / m2. The third composite layer 8 may have a thickness between 0.3 mm and 3 mm.
    [0104]
    [0105] Figure 2 illustrates a schematic view of a cross section of a composite panel according to a second embodiment of the invention. The embodiment according to Figure 2 differs from the embodiment of Figure 1 only by the following. The elements analogous to those of the first embodiment bear the same references as those of the first embodiment.
    [0106]
    [0107] The third composite layer 8 does not comprise an additional thermoplastic binder. The third composite layer 8 may be identical to the first composite layer 4
    [0108]
    [0109] An installation used to produce a composite panel component according to the invention is shown in Figure 3. More particularly, Figure 3 schematically shows the production steps of a precursor material 50 of the second composite layer 6 with a precursor production facility 100.
    [0110]
    [0111] The precursor material 50 comprises the fibers of the second type of fibers 20 and the second thermoplastic binder material 22. In particular, the precursor material is agglomerated grains 52 comprising the fibers of the second type of fibers 20 and the thermoplastic binder material 22.
    [0112]
    [0113] The precursor production facility 100 comprises a waste entrance 102, a precut station 104, an agglomeration station 106, a grinding station 108, a screening station 110 and an exit station 112.
    [0114]
    [0115] Production of the precursor material 50 begins at the waste inlet 102 in which the waste elements 120 comprising the second thermoplastic binder material and fibers of the second type of fibers are introduced. Here, the second type of fibers is used for fibers that are made of the same material as the fibers of the second type of fibers, but their length could be greater than the fibers in the second composite layer of the composite panel. The waste elements are, for example, elements that are the result of the production of panels of natural fiber composite materials or the waste elements are parts at the end of their useful life and have a minimum dimension of between 10 cm and 1 m. The waste elements 120 are cut into smaller elements 122 by the precut station 104. The smaller elements have, for example, a minimum dimension of between 5 cm and 10 cm. The smaller elements 122 are then agglomerated in the agglomeration station 106 and introduced into the milling station 108. In the milling station 108, the smaller elements 122 are milled to form grains of earth 124 having a size between 5 mm and 7 mm. The ground grains 124 are then screened at the screening station 110 and the agglomerated grains 52 are obtained.
    [0116]
    [0117] The precursor material 50 is then collected in containers.
    [0118]
    [0119] Figure 4 shows a schematic view of a panel manufacturing facility 200 to produce a composite panel 2 according to the invention.
    [0120]
    [0121] The panel manufacturing facility 200 comprises:
    [0122] - a first precursor source 202 adapted to provide a precursor material 204 of the first composite layer 4, for example, a first composite fiber web,
    [0123] - a second precursor source 206 adapted to provide the precursor material 50 of the second composite layer 6,
    [0124] - a third precursor source 210 adapted to provide a precursor material 212 of the third composite layer 8, for example, a third band of composite fiber,
    [0125] - a drying station 214, for example, an infrared heater, adapted to dry the precursor material 50 provided by the second precursor source 206, and
    [0126] - a joining device 220 adapted to join the precursor material 204 of the first composite layer 4, the precursor material 50 of the second composite layer 6 and the precursor material 212 of the third composite layer 8, in order to obtain a composite band 222,
    [0127] - an accumulator device 224 of the composite band 222, and
    [0128] - a cutting device 226 adapted to cut the composite band 222 into composite panels 2.
    [0129]
    [0130] The joining device 220 comprises a calendering unit 230, a rolling device 232 comprising an upper belt 234 and a lower belt 236. The rolling device 232 also comprises a heating section 238 and a cooling section 240. The device Lamination can also be configured as a puncture device in which the first composite layer, the second composite layer and the third composite layer are joined together.
    [0131]
    [0132] Composite panels 2 according to the invention are produced as follows:
    [0133]
    [0134] The precursor material 50 is disposed on the precursor material 212 of the first composite layer 4 and subsequently dried using the drying station 214. The precursor material 204 of the third composite layer 8 is disposed on the dry precursor material 50 and the three materials precursors 212, 50 and 214 are introduced into the joining device 220.
    [0135]
    [0136] The three introduced precursor materials 204, 212 and 50 are calendered by the calendering unit 230.
    [0137]
    [0138] The three calendered precursor materials 204, 212 and 50 are heated by the heating section 238 at a temperature above the melting temperature of the thermoplastic binder materials and pressed together, while the thermoplastic binder materials are in a molten state. . Then, the three precursor materials 204, 212 and 50 are cooled until the thermoplastic binder materials solidify, thereby obtaining the composite band 222.
    [0139]
    [0140] The composite band 222 is then cut into composite panels 2 by the cutting station 226.
    [0141]
    [0142] The composite panel 2 according to the invention is advantageous, since it is economically produced thanks to the recycled fibers and the thermoplastic binder material. The composite panel 2, thanks to its structure is also relatively rigid for a given thickness and is easy to use in other manufacturing processes.
    [0143] In an alternative embodiment, the precursor of the second composite layer is an intercalated layer in which the recycled material forms a central layer that is covered on both sides with a thermoplastic film, for example, a polypropylene film. The method of producing this precursor may be similar to the method shown in Figure 4. In this case, the recycled material is disposed between the two thermoplastic films 202, 212. An advantage of this embodiment is that said precursor is coherent, this It is in contrast to a granular precursor. The interleaved layer is laminated with the first and the second composite layer.
    权利要求:
    Claims (10)
    [1]
    1. Composite panel (2), in particular, composite laminated panel, comprising a first composite layer (4) comprising fibers of a first type of fibers (14), a second composite layer (6) comprising fibers of a second type of fibers (20), and a third composite layer (8) comprising fibers of a third type of fibers (30), characterized in that
    - the first type of fibers are carbon fibers,
    - the second type of fibers are natural fibers,
    - the first composite layer comprises a first thermoplastic binder material (16),
    - the second composite layer comprises a second thermoplastic binder material (22),
    - the third composite layer comprises a third thermoplastic binder material (32),
    and because the third type of fibers are natural fibers with an average length greater than the average length of the second type of fibers.
    [2]
    2. Composite panel according to claim 1, wherein the first composite layer does not comprise natural fibers and the second composite layer does not comprise carbon fibers.
    [3]
    3. Composite panel according to claim 2, wherein
    - the fibers of the third type of fibers represent between 40% and 55% by weight of the third composite layer (8),
    - the third thermoplastic binder material (32) represents between 35% and 50% by weight of the third composite layer (8),
    The fibers of the third type of fibers (30) and the third thermoplastic binder material (32) together represent 85% to 100% by weight of the third composite layer.
    [4]
    4. Composite panel according to claim 2 or 3, wherein
    the third composite layer (8) comprises an additional thermoplastic binder material (34) which amounts to up to 15% by weight of the third composite layer, in particular the fibers of the third type of fibers, the third thermoplastic binder material and the additional amount of Thermoplastic binder material amounts to 100% by weight of the third composite layer.
    [5]
    5. Composite panel according to claim 4, wherein
    the additional thermoplastic binder material (34) is different from the third thermoplastic binder material, in particular, the third thermoplastic binder material being polypropylene (PP) and the additional thermoplastic binder material being a polyester, such as PET.
    [6]
    6. Composite panel according to any one of the preceding claims, wherein the first, third and / or additional thermoplastic binder material (16, 22, 32, 34) is in the form of fibers before laminating the first, second and third layers compound.
    [7]
    7. Composite panel according to any one of the preceding claims, wherein the first and second thermoplastic binder materials (16, 22) comprise polypropylene (PP), and in particular consist of polypropylene.
    [8]
    8. Composite panel according to any one of the preceding claims, wherein the first type of fibers are recycled fibers and / or the second type of fibers are recycled fibers.
    [9]
    9. Method for obtaining a composite panel according to any one of the preceding claims, comprising the steps of:
    - provide a precursor of the first composite layer (4),
    - provide a precursor of the second composite layer (6),
    - provide a precursor of the third composite layer (8),
    - superimposing the precursors of the first, second and third layers composed one on top of the other, such that the precursor of the second composite layer is positioned between the precursor of the first composite layer and the precursor of the third composite layer,
    - laminating the precursors of the first, second and third composite layers with respect to each other by heating the composite layers above the melting point of at least one of the thermoplastic binder materials, and
    - cooling the heated precursors of the first, second and third composite layers.
    [10]
    10. The method of claim 9, wherein the precursor of the second composite layer comprises a recycled composite material comprising natural fibers and a thermoplastic binder material.
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    法律状态:
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    优先权:
    申请号 | 申请日 | 专利标题
    DE102018113888.1A|DE102018113888A1|2018-06-11|2018-06-11|Composite plate and corresponding method|
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