Multi-layer fabric, use thereof and method for producing composites
AssigneeC. Cramer, Weberei, Heek-Nienborg, GmbH & Co. KG
InventorJohannes Cramer
Life of this patent
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Abstract
This present invention relates to a multilayered fabric consisting of several twin layers, whereby each twin layers is constructed from two layers, namely one layer from structurally arranged reinforcement fibres Vo, Vm and Vu such as for example carbon fibres, and one layer from structurally arranged thermoplastic matrix fibres M1 and M2, such as for example PEEK fibres. Several twin layers are connected with binder fibre B. Additionally the invention comprises use of the multilayer fabric as a semi-finished product and for manufacture of composites plus a process for manufacture of composites using a special multilayered fabric with an “Advanced Synchron Weave” zero crimp fabric structure (FIG. 1).
Claims19
A dry thermoplastic prepreg for the manufacture of composites, comprising a multilayer fabric comprising reinforcement fibres and thermoplastic matrix fibres arranged in a plurality of textile twin layers,
- wherein each twin layer consists of two layers, namely one layer of structurally arranged identical or differing reinforcement fibres and one layer of structurally arranged identical or differing thermoplastic matrix fibres and whereby each of the structurally arranged matrix fibres in a layer is arranged in a predetermined position relative to a reinforcement fibre in the adjacent layer, the layers of the twin layers are joined one to the other by binder fibres fed through at least two twin layers, and the twin layers are not displaceable one relative to the other.
A process for the manufacture of non-porous lightweight composites comprising the steps of:
- manufacturing a multilayer fabric, comprising several twin layers, whereby one twin layer per layer includes one layer of aligned reinforcement fibres structurally arranged but without binding and one layer each of structurally arranged thermoplastic multifilament matrix fibres and where all layers are connected by binding fibres;
- introducing the multilayer fabric into a press, whereby the reinforcement fibres adopt a predetermined orientation;
- subsequent heating of the textile multilayer fabric to a melting temperature commensurate with the flow range of the matrix fibres, whereby under pressure the multilayer fabric is compressed to form an homogenous, compact fibre-reinforced composite and which can be shaped and whereby air enclosed in the multilayer fabric escapes;
- and
- cooling the compound to obtain the desired composite, in which the reinforcement fibres provided in the predetermined orientation are embedded in the thermoplastic matrix formed in the matrix fibre material in the form of a non-woven layer.
Dependencies are inferred from the claim text.