• 专利附录
  • 专利说明
  • 权利要求
  • 类似技术
  • 同族专利
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  • 优先权
    • 专利摘要:
    The invention relates to a method of manufacturing a composite product sheet or strip comprising the following steps: - Provide polymer particles and a lattice comprising an upper face and a lower face opposite to the upper face, the upper face being intended receiving polymer particles; Sprinkling the upper face of at least a portion of the mesh with the polymer particles to cover said upper face with polymer particles; Heating a portion of the lattice covered with the polymer particles while keeping the upper face covered with regard to a heating element, said heated portion of the mesh being kept flat and without contact on the upper face and on the lower face of said portion during the heating. The invention also relates to a device for manufacturing said composite product, said composite product and its use.
    公开号:FR3073167A1
    申请号:FR1771167
    申请日:2017-11-06
    公开日:2019-05-10
    发明作者:Christian Fischer；Julien Rion；Sophie De Riijk
    申请人:BCOMP SA；
    IPC主号:
    专利说明:

    Technical Field [0001] The present invention relates to a method for manufacturing a composite product and a device for manufacturing such a product.
    STATE OF THE ART [0002] Composite products are conventionally used as a reinforcement structure or framework, to improve the mechanical properties of a part.
    A composite product frequently includes an assembly of wires and a matrix made of a polymer. Wire assembly can take many forms.
    WO2015121583 describes the manufacture of a composite in the form of an assembly of wicks impregnated and woven into strips. The strips typically have a width around 100 mm. In this method, the locks are impregnated on a fluidized bed. Then, the wicks are calibrated, in the sense that they are compressed in a heated calender which gives the desired dimensions to each wick.
    Document WO2010034771 describes a polyamide composite article composed of a fabric or assembly of wires, the wires being welded to one another by a polyamide resin. The polyamide impregnation of the threads is done under pressure by means of a hydraulic press. This type of impregnation requires equipment that is complex to install, for example presses with molds adapted to the shape and dimensions of the fabric.
    The Applicant wishes to manufacture composite products comprising an assembly of wires impregnated with polymer and in the form of a grid, in other words a trellis. Such impregnated mesh can be used as such, or more frequently as semi-finished products to be coated with resin or polymer in order to serve as reinforcements in panels, or other elements, flexible or rigid composites.
    In an assembly of wires in the form of a grid, when dusting the polymer particles on the grid, the polymer particles can pass through the grid, via the opening of the mesh of the grid. For this reason, the grid generally rests on a conveyor belt, which moves the grid from the dusting to the heating. But this solution is not satisfactory: during dusting the polymer particles are deposited on the wires but also in the opening of the mesh of the grid. In this case, during heating, the impregnation of the wire is not satisfactory since the polymer melts and tends to accumulate between the grid and the strip. In addition, after heating, the mesh opening is blocked by polymer, it frequently happens that the grid remains stuck on the strip. The takeoff of the grid leads to a degradation of the impregnation of the grid.
    [0008] Thus, the existing techniques do not make it possible to obtain a composite product based on a grid of wires. There is thus a need for a method of manufacturing a composite product comprising an assembly of wires in the form of a grid.
    Brief Summary of the Invention An object of the present invention is to provide a process which is free or which minimizes the limitations of known processes.
    Another object of the invention is to provide a composite product comprising an assembly of lattice wires.
    Another object of the invention is to provide a composite lattice product having improved mechanical properties, for example flexural strength and resistance to impact or impact.
    Another object of the present invention is to provide a composite product comprising a lattice of son based on vegetable fibers, in particular flax.
    According to the invention, these aims are achieved in particular by means of a process for manufacturing a composite product in sheet or strip form, the process comprising the following steps:
    BCOMP-4-EN
    - Provide polymer particles and a mesh formed of intertwined son, the son being fiber-based, said mesh comprising an upper face and a lower face opposite the upper face, the upper face being intended to receive the polymer particles;
    - Sprinkle the upper face with at least a portion of the mesh with the polymer particles to cover said upper face with the polymer particles;
    - Heating the portion of the lattice covered with polymer particles while maintaining the upper face covered with regard to a heating element, the polymer particles being heated to a temperature at least equal to the melting temperature of the polymer, said heated portion of the lattice being kept flat and without contact on the upper face and on the lower face of said portion during heating.
    This solution has the particular advantage over the prior art of allowing asymmetric impregnation of the son of the mesh. For this, the particles are sprinkled on the upper face of the lattice, then said face is placed at the sight, that is to say opposite, of a heating element. During heating, the heated portion is held flat in front of a heating element to allow homogeneous heating of the heated portion. Keeping a flat portion prevents the molten polymer from moving to either side of the heated portion. Furthermore, also promotes uniform heating over the flat portion of the lattice. Heating from the upper side, on a portion kept flat and without contact, allows an asymmetrical impregnation to be obtained.
    When heating the heated portion is also maintained without contact on the upper face and on the lower face. In other words, the heated portion is suspended, free of any contact, no pressure is exerted on the heated portion during the impregnation of the polymer in the wire. For example, no element of the heating station comes into contact on the upper or lower face of the heated portion. For example, the heated grid portion is not on the conveyor belt. Thus, the molten polymer can be distributed without constraint all around the wires of the heated portion.
    BCOMP-4-FR For example, if the heating is provided by an infrared oven comprising a chamber equipped with infrared lamps as a heating element: there is no contact between the upper face and the infrared lamps . There is also no contact between the underside and the bottom edge of the chamber. This makes it possible not to disturb the distribution of the molten polymer on the wires of the heated portion.
    Part of the molten polymer permeates the upper face. Another part of the molten polymer flows by gravity around the edge of the wire and gradually impregnates the wire as it flows. Thus, an asymmetrical impregnation or impregnation gradient is observed from the upper face to the lower face: the heated portion of the mesh has a greater impregnation on the upper face than on the lower face. In other words, the wire section of the heated portion has an asymmetrical impregnation: on the lower part of the wire, there is less molten polymer available than on the opposite part, the impregnation is thus less deep. For example, the impregnation depth is typically 40-80% of the radius of the wire in the upper part, 20-60% of the radius in the middle part and 10-40% in the lower part.
    It is advantageous to be able to manufacture a composite product with a higher quantity of polymer on the upper face because this strengthens the bending stiffness, when this composite is used as a reinforcement grid on a base material, for example a mat. . In addition, this makes it possible to reinforce the resistance to impact during an impact or a load with an external element: the wire does not break in a clear manner but slowly frayed, retaining a stabilizing net effect.
    Advantageously, the product according to the invention has improved mechanical properties while remaining light, since the impregnation is asymmetrical, which limits the mass of polymer. A symmetrical impregnation would significantly increase the weight of the composite product without significantly increasing the mechanical properties, in particular the rigidity.
    Thus, surprisingly, the product according to the invention is generally lighter than existing composite products having a
    BCOMP-4-FR comparable strength, but it improves mechanical properties, including stiffness or resistance to load or impact.
    The composite products according to the present invention are in the form of a plate or strip: they can be easily associated with another part, by bonding or welding, to reinforce said part. For example, in the automotive industry, a sheet or strip of composite product according to the present invention can be used as reinforcement on a door trim or dashboard or any other interior car trim piece. The sheet or the strip is laminated on a base material, such as for example a non-woven felt of vegetable fibers and polypropylene and this assembly is heated above the melting point of the polymer and formed in a mold under press.
    Advantageously, according to the invention, the heating of the portion of lattice covered with polymer particles is carried out essentially from above, that is to say by the upper face. Thus, the molten polymer protects the fibers of the heating element, to prevent the wires from being degraded, for example burned, by the heating element. Advantageously, the polymer absorbs part of the heat, so that the fibers of the yarn are less heated than the polymer, which makes it possible to preserve them.
    According to one embodiment, the method comprises:
    - Cooling said heated portion of the mesh, said portion being kept flat and without contact on the upper face and on the lower face of said portion during cooling, the cooling step taking place after the heating step.
    The cooling allows the molten polymer which has impregnated the wire or which is on the surface of the wire, to pass from the molten state to the solid state. Advantageously, during cooling, similarly to heating, the portion comprising molten polymer is kept flat and without contact. In other words, there is no pressure or constraint or contact on the impregnated wire covered with molten polymer, and the mesh is kept flat. In this case, the distribution of the molten polymer is subject only to gravity, no external stress disturbs the distribution of the polymer. For example, when the lattice rests on a support or when it is inclined, and the molten polymer solidifies, the asymmetric impregnation of the lattice can be
    BCOMP-4-FR modified by the inclination of the trellis, or by the support under the trellis. Furthermore, if the trellis is on a support during cooling, the trellis can remain stuck on the support. Finally, any contact with a support can modify the circular geometry of the impregnated wires, which is advantageous for the reinforcing effect of the mesh. Thus, keeping the trellis flat and without contact during cooling makes it possible to avoid these drawbacks and to maintain the asymmetrical distribution of the polymer on the trellis during cooling and not to alter the circular geometry of the wires.
    According to one embodiment, the method comprises:
    - - Laminate the lower face and / or the upper face of the heated portion on a mat.
    The mat can be laminated on the lower face or alternatively on the upper face of the portion of the heated mesh. Preferably, the mat is laminated on the underside of the heated portion. The Applicant has observed that when the mat is bonded to the lower part of the impregnated wire, opposite the upper part which comprises more polymer, the mechanical properties are better. It is also possible to make a sandwich stack, the heated portion being between two mats. Laminating the mesh on a mat significantly increases the rigidity of the mat with reduced weight.
    Preferably, the rolling step takes place between the heating step and the cooling step. In this case, at least part of the polymer is still molten, which makes it possible to promote the adhesion between the mat and the lattice. The mat is brought into contact with the molten polymer. Advantageously, the contacting is done with a very low pressure or without pressure on the lattice, to minimize the impact of rolling on the thickness (the section) of the lattice, because the wires of the lattice acting as reinforcing ribs, their effect is directly related to the final thickness of the mesh.
    For example, the mat is laminated on the underside of the mesh. For example, the means for laminating include an unwinding roller, a contact roller and a pressure roller. The unrolling roller unrolls the mat towards a contact roller which presents the mat facing the underside of the trellis. The pressure roller and the contact roller are separate
    BCOMP-4-FR and other of the trellis, respectively with regard to the lower face and the upper face.
    Preferably, the spacing between the contact roller and the underside of the mesh corresponds to the thickness of the mat or slightly greater, so that the contact roller does not exert pressure or minimal pressure on the underside of the trellis.
    Preferably, the spacing between the pressure roller and the contact roller corresponds to the thickness of the lattice at the outlet of the heating, added to the thickness of the mat in the case of mat. This makes it possible to minimize the pressure on the mesh and the deformation thereof.
    Preferably, the pressure roller is covered with a non-adhesive material, for example a silicone or Teflon component, so as not to adhere to the upper or lower face of the impregnated mesh. The contact surface is also preferably soft and elastic, in order to adapt to the geometry of the trellis and to minimize the crushing of the wires.
    Alternatively, it is possible to laminate the mat on the mesh after cooling. In this case, it is possible to glue the mat on the mesh using an adhesive. Another possibility is to reheat the mesh to melt at least part of the mesh and make the mat adhere. Another possibility is also to heat a prepreg mat to melt the thermoplastic matrix which will then adhere to the mesh. Alternatively, it is possible to heat both the lattice and the mat to melt the matrix of the two components and adhere them.
    In one embodiment, the upper face of at least a portion of the mesh is covered with at least the same surface mass of polymer particle as the surface mass of the non-impregnated mesh. For example, a mesh of 200 g / m 2 will be sprinkled with at least 200 g / m 2 of polymer particles. The Applicant has observed that this allows good impregnation results.
    For example, in one embodiment, the dusting is carried out by a particle diffuser, for example a vibrating screen, the ratio
    BCOMP-4-FR between the mass of dusted particles Ms and the mass of particles deposited Md on the upper face being greater than 2, the ratio Ms / Md greater than 3, preferably greater than 4, preferably greater than 5. In this embodiment, the Applicant has discovered that it is possible to deposit a sufficient quantity of particles on the threads despite the mesh openings. When the powdered mass Ms is in excess relative to the deposited mass Md, in particular Ms / Md of between 5 and 9, the mass Ms is sufficient to obtain a satisfactory impregnation. For example, for a mesh of 14x14 mm mesh, an Ms / Md between 5 and 6 provides interesting results; for a mesh of 28x28 mm mesh, an Ms / Md between 7 and 9 provides interesting results.
    The purpose of the dusting station is to deposit polymer particles on the mesh. There are several devices to perform this action: for example the dusting station includes a drum with a system of combs around the perimeter, the powder on the drum is deposited (falls) then on a vibrating sieve.
    Alternatively, one could use a distributor with a distribution control means to deposit particles only on the wire, and those in a determined amount.
    In one embodiment, the grid is arranged on a support during the dusting, for example a belt of a conveyor. At the end of the dusting, at least a portion of the sprinkled grid leaves the support, before heating, so as to drop by gravity the particles accumulated in the mesh openings and to recycle them for the dusting of another section of the trellis.
    According to one embodiment, the method comprises:
    - Preheat at least a portion of the trellis before dusting.
    Preheating notably allows the mesh to be dried when the wires are wet or contain moisture, as is often the case with vegetable fibers. In addition, this improves the adhesion of solid polymer particles which adhere more easily to a preheated wire.
    According to one embodiment, the method comprises:
    BCOMP-4-EN
    - Cut the lattice in sheet or strip after the heating or cooling step.
    In one embodiment, the particles have a size between 100 pm and 600 pm.
    According to one embodiment, the lattice has a polygonal mesh, for example rectangular or square. Alternatively, the trellis can have a mesh comprising curved edges.
    In one embodiment, the lattice comprises a mesh with a mesh opening greater than or equal to 1 cm, preferably between 1 cm and 6 cm, preferably between 1 cm and 3 cm.
    According to one embodiment, the threads are based on vegetable fiber, for example flax or from cellulosic fibers. In one embodiment, the fiber is chosen from flax, hemp, kenaf, nettle, jute, abaca, sisal. The yarns produced from vegetable fibers generally have a certain twist introduced during spinning, which makes it possible to improve the resistance to radial compression of the yarn, which will therefore have a greater thickness after rolling on a mat and will consequently improve the reinforcement effect in flexion of the trellis. The density of vegetable fibers is also low, of the order of 1.2-1.6, which makes it possible to obtain a greater thickness of trellis for a given weight, and thus further improve the reinforcing effect of the trellis. Due to their natural origin, the use of these fibers also makes it possible to reduce the ecological impact of the production of parts reinforced by the mesh.
    According to one embodiment, the threads are based on synthetic fiber, for example based on polymer, carbon fiber, glass fiber, basalt fiber or a mixture of these different types of fibers .
    According to another embodiment, the wire is based on animal fiber, for example silk.
    According to another embodiment, the threads are based on vegetable fiber and at least one non-vegetable fiber, for example a fiber
    BCOMP-4-FR synthetic. In this embodiment, the wire is based on at least two different fibers.
    In one embodiment, the heating element is an infrared oven or a convection oven.
    According to one embodiment, the polymer has a melt index greater than or equal to 30 (according to standardized test, g / 10 min at 2.16 kg).
    In one embodiment, the polymer is chosen from polypropylene, polyethylene, polyamide or co-polyamide, polyester or co-polyester, thermoplastic polyurethane, co-Polyoxymethylene, thermoplastic cellulose esters (Cellulose acetate propionate), polylactic acid (PLA) or derivatives thereof or mixtures thereof.
    In one embodiment, the polymer is chosen from thermoplastic polymers, for example polypropylene, polyethylene, polyamide or co-polyamide, polyester or co-polyester, thermoplastic polyurethane, co-Polyoxymethylene, esters of thermoplastic cellulose (Cellulose acetate propionate), polylactic acid (PLA).
    The composite product serves as reinforcement or framework to guarantee the rigidity of the material, in particular the flexural rigidity. The product also improves impact or impact resistance.
    The invention further relates to a device for manufacturing a composite product comprising:
    A dusting station comprising means for dusting polymer particles on a lattice formed of intertwined threads, the threads being fiber-based, said lattice comprising an upper face and a lower face opposite the upper face, said means for dusting allowing dusting the upper face of at least a portion of the mesh with the polymer particles to cover said upper face with polymer particles;
    BCOMP-4-EN
    A heating station positioned downstream of the dusting station, said heating station comprising a heating element for heating a portion of the mesh covered with the polymer particles, the polymer particles being heated to a temperature at least equal to the temperature of polymer melting;
    characterized in that the device comprises displacement means arranged to keep said heated portion of the mesh flat and without contact on the upper face and on the lower face of said portion during heating.
    The displacement means are arranged to move said portion of the mesh successively from the dusting station to the heating station (then to the cooling station if the device comprises a cooling station). In addition, the displacement means are arranged to keep said heated portion of the mesh flat and without contact on the upper face and on the lower face of said portion being heated. In other words, when the portion moves opposite the heating element, or is fixed under the heating element, the displacement means keep it flat and without contact on the lower and upper faces of the heated portion The displacement means keep the mesh in contact outside the heated portion.
    The mesh works in traction, it is stretched between the displacement means which make it possible to keep the mesh flat during heating, and optionally cooling and dusting. The displacement means hold and tension the trellis in contact with the trellis, but outside the portion of the trellis which is at the heating station, and optionally at the cooling station. In other words, it is important to avoid contact on the useful portion of the lattice, that which is heated, during heating and optionally cooling. For example, the displacement means comprise an unwinder, a reel, and a traction unit, these three elements being positioned outside the portion of the heated lattice, and optionally outside the portion of the cooled lattice.
    The unwinder unwinds from the raw lattice, that is to say without polymer, in the direction of the reel. The unwinder exerts a pulling force on the trellis so that the trellis is under tension.
    BCOMP-4-FR The reel cools the cooled composite product, for example by a cooling unit or in the open air, downstream of the heating.
    The unwinder and the traction unit cooperate to control the tension of the trellis (then of the composite product) and the unwinding speed. The traction unit comprises, for example, two rollers on either side of the composite product: an upper roller and a lower roller positioned respectively opposite the upper face and the lower face of the trellis. The upper and lower rollers rotate in opposite directions, one clockwise, the other counterclockwise, to advance the mesh (then the product) from the unwinder to the reel. Alternatively, the traction unit may comprise two strips facing each other, or a strip facing a cylinder.
    The movement speed is for example between 0.5 m / min and 5 m / min, preferably between 1.0 and 2.0 m / min, for example 1.5 m / min. The speed of movement depends on the heating power available: the higher the speed, the greater the heating power must be to guarantee the melting of the polymer. In particular, the applicant has obtained good results with infrared heating with a power of 115 kW, over the width of the trellis, for example 1400 mm, and a speed of 1.5 m / min.
    The space between the upper roller and the lower roller is chosen to control the pressure exerted on the composite product. The pressure must be sufficient to entrain the composite product. The pressure must be limited so as not to degrade the composite product. For example, the spacing is between 0.8 and 1.5 mm.
    In one embodiment, the device comprises a cooling station downstream of the heating station to cool said portion, said displacement means making it possible to keep said heated portion of the mesh flat and without contact on the upper face and on the underside of said portion during cooling.
    The cooling station cools the polymer to allow solidification of the polymer. For example, the cooling station comprises at least one fan which stirs gas, for example
    BCOMP-4-FR example air or an inert gas, to cool the polymer. Alternatively, compressed air can be directed to the mesh to cool it down.
    In one embodiment, the heated portion is kept contactless and flat during heating, cooling, and between heating and cooling. Thus, no contact alters the geometry of the impregnated wires from the heating to the cooling.
    In one embodiment, the device comprises a rolling station for laminating the impregnated mesh on a mat, in particular the lower face and / or the upper face of the heated portion on a mat.
    Preferably, the rolling station is downstream of the heating station.
    In one embodiment, the device comprises a preheating station, upstream of the dusting station, said station comprising a preheating element for preheating at least the portion of the mesh which will be covered with particles.
    According to one embodiment, the device comprises a recycling station downstream from the dusting station. The recycling station makes it possible to recover the polymer particles deposited in the opening of the mesh of the mesh during the dusting, these particles being able to be reused. The recycling station is downstream from the dusting station.
    According to one embodiment, the device comprises a belt conveyor for holding the grid during the dusting. The belt conveyor which holds the trellis is upstream of the heating, it supports the tension of the trellis, which determines the height of the trellis under the heating and favors the flat position of the trellis at the entrance of the heating station and during the heating .
    For example, when the device comprises a belt conveyor for moving the trellis during dusting, the recycling station comprises a tank into which the particles of the mesh opening of the grid are poured deposited on the conveyor belt .
    BCOMP-4-FR In one embodiment, the device comprises a cutting station downstream of the heating station, preferably downstream of the cooling station. The cutting station allows the composite product to be cut into strips or sheets of determined size depending on the use of the composite product.
    According to the present invention, the composite product is in sheet or strip. A sheet or strip designates a planar object, defined in a plane (x, y), and in which the thickness along the z axis is much less than the dimensions along the x and y axes. A strip is a sheet in which in one plane (x, y), one of the dimensions is much greater than the other.
    In the present invention, the term trellis is synonymous with grid and designates an assembly of wires which intersect to define meshes. To form the meshes, the wires are joined together, for example glued or welded, or else held by support wires.
    In the present invention, a wire is formed of fibers.
    Advantageously, the impregnated mesh is more easily manipulated. The fibers of the threads are at least partially embedded in the polymer. The wires are joined to each other, the assembly does not come apart during handling.
    The invention also relates to the use of a polymer impregnated mesh to manufacture a composite product comprising said mesh and a support, said polymer making it possible to secure the mesh on said support. The use of a pre-impregnated mesh, with a coating of molten polymer, makes it easier to adhere and fix the mesh to the support. The support may be a mat or any other flat support to be reinforced.
    The invention also relates to a composite product comprising on the one hand a lattice prepreg of a polymer, and on the other hand a mat prepreg of a polymer identical to or different from the polymer of said lattice. The mat and mesh are pre-impregnated, which makes it easier for the mesh to adhere to the mat.
    BCOMP-4-FR In the present invention, the term “mat” designates a support or a plate, in other words a sheet or a felt, composed of fibers organized in a random manner. A mat is a non-woven material. The present invention preferably relates to lamination on a mat, but the invention is not limited to this type of support. It is possible to use supports composed of unidirectional, multidirectional fibers, woven or nonwoven.
    According to the present invention, the term "composite product" or "composite" is a product which comprises at least two different and not very homogeneous materials which are associated. The combination gives all of the properties that none of the components taken separately has. In the present invention, the composite product can be a wire mesh and a polymer, the wires being at least partially impregnated with polymer. Said lattice of prepreg son can be embedded in a polymer identical or different from the polymer of said wire. The composite product can also be a lattice made of prepreg son, said lattice being laminated on a mat, said mat possibly also being prepreg of a polymer identical to or different from the polymer of said yarn. In this case, the use of a prepreg lattice laminated on a prepreg mat or not facilitates adhesion of said trellis. The composite product is then a laminated composite.
    The embodiments described for the method according to the invention apply mutatis mutandis to the device, to the composite product and to the use of a composite product according to the invention, and vice versa.
    Brief description of the figures Examples of implementation of the invention are indicated in the description illustrated by the appended figures in which:
    Figure 1 shows a general view of a raw mesh, without polymer, usable in the invention;
    Figure 2 shows a block diagram of the invention according to a first embodiment;
    Figure 3 shows a general view of a composite product obtained according to the first embodiment;
    BCOMP-4-FR [0081] FIG. 4 represents a section of a wire of the composite product according to the first embodiment;
    Figure 5 shows in block diagram of the invention according to a second embodiment;
    Figure 6 shows a general view of a composite product according to the second embodiment of the invention.
    Example (s) of Embodiment of the Invention Two embodiments of the present invention are shown in Figures 1 to 6, but the invention is not limited to the embodiments shown in Figures 1 at 5.
    FIG. 1 represents a trellis 1 which can be used in the invention for manufacturing a composite product 2. The trellis 1 shown in FIG. 1 is the trellis before dusting and impregnation, in other words a raw trellis, that is to say without polymer. The trellis 1 comprises 3 crisscrossed wires. The wires 3 are glued or sewn to each other at each intersection 4. The trellis 1 has a rectangular polygonal mesh 5 of dimension 14x14mm or 28x28mm. But it is also possible to use lattices with meshes of 10 to 60 mm, for example polygonal.
    The trellis 1 comprises an upper face 6 and a lower face 7.
    The wires 3 are based on flax fiber. In this embodiment, the threads are exclusively based on flax, but it is possible to use threads made of a different material, or threads made from several different types of fiber, for example hemp, kenaf, nettle, jute, abaca, sisal, cotton, polymer fibers, carbon fibers, glass, basalt, aramid.
    2 shows a device according to a first embodiment for manufacturing a composite product 2 shown in Figure 3. In this embodiment, the composite product 2 is a prepreg 10 which comprises a mesh 1 impregnated with polymer 11.
    BCOMP-4-FR The device of this first embodiment shown in FIG. 2 is a production line 12 which includes a dusting station 13, a recycling station 14, a heating station 15, a heating station cooling 16.
    To ensure the movement of the mesh 1 from the heating station 13 to the cooling station 16, the chain 12 comprises an unwinder 17, a traction unit 18 and a winder 19. The unwinder 17 unwinds from the wire mesh 1 said raw 3, without polymer, towards the dusting station 13. The traction unit 19 is positioned after the cooling station 14 and pulls the trellis 1 in front of each station of the chain 12. The traction unit 18 comprises a roller upper 20 vis-à-vis the upper face 6 and a lower roller 21 vis-à-vis the lower face 7. The trellis 1 is held between the upper rollers 20 and lower 21 which makes it possible to tow said trellis 1. The reel 19 wraps the prepreg 8 at the end of the chain 12. In this embodiment, the mesh moves at a speed of 1.5 m.miri 1 .
    The chain 12 makes it possible to successively pass a portion of mesh through the dusting stations 13, recycling 14, heating 15 and cooling 16. Before the dusting station 13, the portion of mesh 1 is with a wire 3 to l 'rough; after the cooling station 16, said portion of raw mesh has been transformed into a portion of prepreg 10.
    At the start of the chain 12, at the outlet of the unwinder 17, the trellis 1 rests on the band of a belt conveyor 22 which holds the trellis 1 facing the dusting station 13 and guides the trellis 1 towards the recycling station 14. In this chain 12, the dusting station 13 is a vibrating screen 28 which sprinkles polymer particles over the entire surface of a portion of the mesh 1, in other words on the wires 3 and in the mesh openings 5 of the trellis. For example, for a 14x14 mm mesh, the sieve sprinkles 1200 to 1300 g.rri 2 of polymer particles (powdered mass Ms) so that after the recycling station, there remain 200 to 240 g.rrT 2 of particles of polymer on the wires 3 (deposited mass Md), the Ms / Md ratio is thus between 5 and 6. In this embodiment, the polymer 11 is polypropylene. For a 28x28 mm mesh, the sieve sprinkles 17001900g.m- 2 (Ms) to obtain 200-240g.m- 2 (Md).
    BCOMP-4-FR [0093] The conveyor belt 22 makes it possible to collect the polymer particles which are in the meshes 5, to transfer them to the recycling unit 14.
    The portion of sprinkled mesh then passes through the heating station 15. The heating station 15 is here an infrared oven 23. The infrared oven 23 heats the portion sprinkled with polypropylene (PP) from above, c that is to say from the upper face 6, at a temperature of 200 to 220 ° C. The PP melts and protects the flax fiber of yarn 3 from infrared radiation, so that the flax stays below 185-190 ° C and does not burn.
    At the outlet of the heating, the heated portion passes through the cooling station 16. In this embodiment, the cooling station 16 comprises air fans (not shown in the figures) positioned facing the upper face 6.
    During heating and cooling, the heated portion is taut and contactless, thanks to the tension imparted by the traction unit 18.
    On leaving the traction unit 18, the prepreg 10 is wound on the reel 19.
    FIG. 4 represents a section of impregnated wire 24 which illustrates the asymmetrical impregnation of the wire 24. The impregnation makes it possible to transform the raw wire 3 into impregnated wire 24. The wire 24 of the prepreg 10 comprises an upper part 25, a central part 27, and a lower part 26. The upper part 25 is the part exposed on the upper face 6 of the trellis; the lower part 26 is the part exposed on the lower face 7 of the trellis 1.
    The upper part 25 is impregnated more deeply than the lower part 26. Indeed, the polymer 9 is deposited on the upper face 6, and melts from the upper face 6. A part of the molten polymer impregnates the upper part 25 of the wire 24. The polymer 11 which does not impregnate the upper part 25 of the wire 24 flows around the periphery of the wire 24 by gravity, and impregnates progressively. Thus, an asymmetrical distribution of the polymer is obtained: on the lower part of the wire 27, there is less molten polymer available than on the opposite part, the impregnation is thus less deep. The depth
    BCOMP-4-FR impregnation is typically 40-80% of the radius of the wire in the upper part, 20-60% of the radius in the middle part and 10-40% in the lower part.
    The central part 27 of the wire 22 is little or not impregnated, most of the polymer being distributed between the upper 25 and lower 26 and the sides of the middle part.
    The molten polymer essentially filled with empty spaces between the fibers making up the raw wire 3, so that the impregnated wire 24 generally has a diameter about 5-20% larger than the raw wire 3. Figure 5 shows a device according to a second embodiment for manufacturing a composite product 2 represented in FIG. 6. In this embodiment, the composite product 2 is a laminated product 100 which comprises a prepreg 10 laminated on a support, here a mat 101.
    The device of this second embodiment shown in Figure 5 is a production line 102 which includes a dusting station 103, a recycling station 104, a heating station 105, a cooling station 106. These stations are the same as those of the first embodiment of the chain 12.
    As in the chain 12 according to the first embodiment, the chain according to the second embodiment comprises an unwinder 107 and a traction unit 108, as well as a belt conveyor, these elements operating as in the chain 12 according to the first embodiment.
    The chain 102 according to the second embodiment makes it possible to manufacture laminated composite 100. For this, the chain 102 comprises a rolling station 130 located between the heating station 105 and the cooling station 106. The rolling station 130 comprises a unwinding roller 131, a contact roller 132 and a pressure roller 133. The mat 101 is wound on the unwinding roller 131. The contact 132 and pressure 133 rollers are positioned respectively opposite the face lower 7 and upper face 6.
    BCOMP-4-FR The unrolling roller 131 unrolls the mat 101 towards the contact roller 132. The contact roller 132 guides the mat towards the lower face 6 of the trellis. The underside 7 comprises at least one part of polymer 11 in the molten state, capable of having an adhesive function. The mat and the prepreg are taken in a vice (“sandwich”) between the contact roller 132 and the pressure roller 133. The spacing between the contact roller 132 and the pressure roller 133 corresponds to a distance slightly less than the sum of the thicknesses of the mat added to that of the impregnated wire 22, typically 5-20% less, so that the mat 101 and the prepreg 10 are pressed lightly on each other. The distance preferably depends on the type of mat. This improves the adhesion of the prepreg 10 to the mat 101, minimizing as much as possible the change in the thickness of the impregnated wire 24.
    In an embodiment not shown, the rolling is carried out on the upper face 6. In another embodiment not shown, the rolling is carried out on the upper face 6 and the lower face 7.
    Downstream of the rolling station 130, the cooling station 105 cools the laminated composite 100 at the outlet of the rolling station 130.
    The chain 102 further comprises a cutting station downstream of the cooling station 10. The cutting station 134 makes it possible to cut the laminated composite 100 into sheet 135 of predetermined size.
    A sheet 135 of laminated composite obtained by the chain 102 is shown in FIG. 6. The sheet 135 comprises a prepreg 10 and a mat 101.
    BCOMP-4-EN
    Reference numbers used in the figures
    lattice
    Composite product
    Raw wire
    Intersection
    stitch
    Upper side
    Lower side
    Polymer prepreg
    Production line
    Dusting station
    Recycling station
    Heating station
    Cooling station
    Dispenser
    Traction unit
    reel
    Upper roller
    Lower roller
    Belt conveyor
    Infrared oven
    Impregnated wire
    Upper part of the impregnated wire
    Lower part of the impregnated wire
    Central part of the impregnated wire Vibrating screen
    Laminated composite
    Mast
    Production line
    Dusting station
    Recycling station
    Heating station
    BCOMP-4-EN
    106107108 Cooling stationDispenserTraction unit 120121122 Upper rollerLower rollerBelt conveyor 130131132133134135 Laminating stationUnrolling rollerContact rollerPressure rollerCutting stationLaminated composite sheet
    BCOMP-4-EN
    权利要求:
    Claims (17)
    [1" id="c-fr-0001]
    1. Process for manufacturing a composite product (2, 10, 100) in sheet or strip form, the process comprising the following steps:
    - Providing polymer particles and a mesh (1) formed of crisscrossed wires (3), the wires (3) being based on fibers, said mesh (1) comprising an upper face (6) and a lower face (7) opposite the upper face (6), the upper face (6) being intended to receive particles of polymer;
    - sprinkle the upper face (6) with at least a portion of the mesh (1) with the polymer particles to cover said upper face (6) with the polymer particles;
    - heating a portion of the lattice covered with particles while maintaining the upper face (6) covered with regard to a heating element (15, 23, 105), the polymer particles being heated to a temperature at least equal to the melting temperature of the polymer, said heated portion being held flat and without contact on the upper face (6) and on the lower face (7) of said portion during heating.
    [2" id="c-fr-0002]
    2. Method according to claim 1, comprising:
    - cooling said heated portion, said portion being held flat and without contact on the upper face (6) and on the lower face (7) of said portion during cooling, the cooling step taking place after the heating step .
    [3" id="c-fr-0003]
    3. Method according to one of claims 1 or 2, comprising:
    - laminate the lower face (7) and / or the upper face (6) of the heated portion on a mat (101).
    [4" id="c-fr-0004]
    4. Method according to claims 2 and 3, wherein the rolling step takes place between the heating step and the cooling step.
    [5" id="c-fr-0005]
    5. Method according to one of claims 1 or 4, comprising:
    - preheat at least a portion of the mesh before dusting.
    [6" id="c-fr-0006]
    6. Method according to one of claims 1 to 5, comprising:
    - cut the mesh (1) into a sheet (135) or strip after the heating step.
    BCOMP_4_fr_rev_rep_OA_clean
    [7" id="c-fr-0007]
    7. Method according to one of claims 1 to 6, in which the fibers are chosen from vegetable fibers, in particular flax, hemp, jute, cotton, kenaf, nettle, abaca, sisal preferably flax.
    [8" id="c-fr-0008]
    8. Method according to one of claims 1 to 7, in which said composite product comprises said prepreg mesh resulting from the heating step and a support, the method comprising:
    - Securing the mesh on said support using said polymer.
    [9" id="c-fr-0009]
    9. Method according to one of claims 1 to 8, wherein said composite product comprises on the one hand a lattice prepreg of a polymer resulting from the heating step, and on the other hand a mat prepreg of a polymer identical or different from the polymer of said mesh, the method comprising:
    - Adhere said prepreg mesh to said prepreg mat.
    [10" id="c-fr-0010]
    10. Device (12, 102) for manufacturing a composite product (2, 10, 100) in sheet form (135) or in strip, the device (12, 102) comprising:
    - a dusting station (13, 103) comprising means for dusting (128) polymer particles on a mesh (1) formed of intertwined threads (3), the threads (3) being based on fibers, said mesh ( 1) comprising an upper face (6) and a lower face (7) opposite the upper face (6), said dusting means (128) making it possible to sprinkle the upper face (6) with at least a portion of the lattice with the polymer particles for covering said upper face (6) with the polymer particles;
    - a heating station (15, 105) positioned downstream of the dusting station (13, 103), said heating station (15, 23, 105) comprising a heating element (23) for heating the portion of the lattice (1 ) covered with particles, the polymer particles being heated to a temperature at least equal to the polymer melting temperature;
    characterized in that the device (12, 102) comprises displacement means (17, 18, 19, 107, 108) arranged to keep said heated portion of the mesh flat and without contact on the upper face (6) and on the underside (7) of said portion during heating.
    BCOMP_4_fr_rev_rep_OA_clean
    [11" id="c-fr-0011]
    11. Device (12, 102) according to claim 10, the device (12, 102) comprising:
    - a cooling station (16, 106) downstream of the heating station to cool said portion, said displacement means (17, 18, 19, 107, 108) making it possible to keep said heated portion of the trellis flat and without contact on the upper face (6) and on the lower face (6) of said portion during cooling.
    [12" id="c-fr-0012]
    12. Device (12, 102) according to one of claims 10 to 11, the device (12, 102) comprising:
    - A rolling station (130) for laminating the upper face (6) and / or the lower face (7) of the heated portion on a mat (101).
    [13" id="c-fr-0013]
    13. Device (12, 102) according to one of claims 10 to 12, the device (12, 102) comprising:
    - A preheating station, upstream of the dusting station (13, 103), to preheat at least the portion of the mesh which will be covered with particles.
    [14" id="c-fr-0014]
    14. Device (12, 102) according to claims 12 and 13, wherein the rolling station (130) is downstream of the heating station (15, 105).
    [15" id="c-fr-0015]
    15. Device (12, 102) according to one of claims 10 to 14, the device (12, 102) comprising:
    - a recycling station (12, 102) downstream of the dusting station (13, 103).
    [16" id="c-fr-0016]
    16. Device (12, 102) according to one of claims 10 to 15, the device (12, 102) comprising:
    - a belt conveyor (22) to hold the trellis (1) during the dusting.
    [17" id="c-fr-0017]
    17. Device (12, 102) according to one of claims 10 to 16, the device (12, 102) comprising:
    - A cutting station (134) downstream of the heating station (15, 105), preferably downstream of the cooling station (16, 106).
    类似技术:
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    EP3670129A1|2020-06-24|Method for producing a fibrous material pre-impregnated with thermoplastic polymer in a fluidised bed
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    同族专利:
    公开号 | 公开日
    FR3073167B1|2020-11-20|
    WO2019087141A1|2019-05-09|
    CN210553147U|2020-05-19|
    引用文献:
    公开号 | 申请日 | 公开日 | 申请人 | 专利标题
    FR2031720A5|1969-02-05|1970-11-20|Verre Textile Ste|
    EP1035156A1|1997-11-26|2000-09-13|Sumitomo Bakelite Co., Ltd.|Processes for the production of prepregs and laminated sheets|
    DE102011011387A1|2011-02-17|2012-08-23|Daimler Ag|Multilayer fiber reinforced plastic composite semi-finished product for preparing body components, comprises layers, where a core layer is arranged from one another on filling bodies that are connected between two edge layers|WO2021009581A1|2019-07-16|2021-01-21|Bcomp Sa|Thin-walled composite product reinforced by hybrid yarns and method for manufacturing such a product|EP1531981A1|2002-06-22|2005-05-25|ORTLIEB, Hartmut|Fabric, mesh fabric or structure consisting of a plastic material, and method for producing one the same|
    FR2936441B1|2008-09-26|2012-12-07|Rhodia Operations|COMPOSITE POLYAMIDE ARTICLE|
    DE102009025981A1|2009-06-16|2011-03-31|Saertex Gmbh & Co. Kg|Process for producing a semi-finished textile product with improved toughness and semi-finished textile|
    WO2012130732A1|2011-03-29|2012-10-04|Sgl Carbon Se|Method for producing a prepreg and an organic sheet that can be obtained therefrom|
    FR3017329B1|2014-02-13|2016-07-29|Arkema France|METHOD FOR MANUFACTURING PRE-IMPREGNATED FIBROUS MATERIAL OF FLUIDIZED BED THERMOPLASTIC POLYMER|FR3103199B1|2019-11-15|2021-12-10|Bcomp Sa|Impregnated yarn, a ribbed thin-walled composite product comprising such an impregnated yarn, and method of manufacturing this yarn and this composite product|
    WO2021185632A1|2020-03-19|2021-09-23|Mubea Carbo Tech Gmbh|Protecting member for a battery structure of an electric vehicle|
    CN113276449A|2021-07-23|2021-08-20|山东泰恒智能环境科技有限公司|Pretreatment paving device for carbon fiber composite material|
    法律状态:
    2019-05-10| PLSC| Publication of the preliminary search report|Effective date: 20190510 |
    2019-11-20| PLFP| Fee payment|Year of fee payment: 3 |
    2020-11-20| PLFP| Fee payment|Year of fee payment: 4 |
    2021-11-22| PLFP| Fee payment|Year of fee payment: 5 |
    优先权:
    申请号 | 申请日 | 专利标题
    FR1771167A|FR3073167B1|2017-11-06|2017-11-06|METHOD OF MANUFACTURING A COMPOSITE PRODUCT|
    FR1771167|2017-11-06|FR1771167A| FR3073167B1|2017-11-06|2017-11-06|METHOD OF MANUFACTURING A COMPOSITE PRODUCT|
    PCT/IB2018/058615| WO2019087141A1|2017-11-06|2018-11-02|Composite product comprising a treillis and a polymer|
    CN201821809984.8U| CN210553147U|2017-11-06|2018-11-05|Composite product|
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