Nonwoven mat, method for production thereof and fibre composite
AssigneeFrenzelit-Werke GmbH & Co. KG
InventorsWilfried Erb, Peter Übelmesser
Life of this patent
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Abstract
The invention relates to a nonwoven mat as half-stuff which contains a high performance thermoplast as melt fiber and a reinforcing fiber, and also a method for producing a nonwoven mat of this type and fiber composites produced from the nonwoven mat.
Claims34
A non-woven mat as an intermediate product for a fibre thermoplastic composite comprising a first fibre made of a thermoplast with a fibre length of between 0.1 mm to 6 mm and having a weight proportion of 30% to 90%, and a reinforcing fibre with a fibre length of 6 mm to 30 mm, the temperature stability of the reinforcing fibre being greater than that of the first fibre and having a weight proportion of 70% to 10%, the first fibre and the reinforcing fibre being bonded merely at the intersection or contact points with 1% to 10% by weight of a binder, the weight proportions being relative to the entire formulation of the non-woven mat, the fiber length of the first fibre being smaller than that of the reinforcing fibre, the non-woven mat having a weight of between 8 g/m2 and 400 g/m2.
A method for producing a non-woven mat for a fibre thermoplastic composite, the mat having a first fibre made of a thermoplast with a fibre length of between 0.1 mm to 30 mm and having a weight proportion of 30% to 90%, and a reinforcing fibre with a fibre length of 0.1 mm to 30 mm, the temperature stability of the reinforcing fibre being greater than that of the first fibre and having a weight proportion of 70% to 10%, the first fibre and the reinforcing fibre being bonded merely at the intersection or contact points with 1% to 10% by weight of a binder, the weight proportions being relative to the entire formulation of the non-woven mat, the fiber length of the first fibre being smaller than that of the reinforcing fibre, the non-woven mat having a weight of between 8 g/m2 and 400 g/m2, the method comprising the steps of:
- dispersing said first fibre and said reinforcing fibre in a dispersion medium,
- filtering the fibre containing dispersion medium through a diagonally running wire belt to form a filtrate,
- compacting the filtrate to form a web,
- drying the web, and
- adding said binder to either the dispersion medium or to the filtrate.
A fibre thermoplastic composite produced from a non-woven mat, the mat comprising a fibre matrix made of a first fibre thermoplast with a fibre length of between 2 mm to 6 mm and having a weight proportion of 30% to 90%, and a reinforcing fibre with a fibre length of 6 mm to 18 mm, the temperature stability of the reinforcing fibre being greater than that of the first fibre thermoplast and having a weight proportion of 70% to 10%, the first fibre thermoplast and the reinforcing fibre being bonded merely at the intersection or contact points with 1% to 10% by weight of a binder before melting of said first fibre thermoplast, the weight proportions being relative to the entire formulation of the non-woven mat, the fiber length of the first fibre thermoplast being smaller than that of the reinforcing fibre, the non-woven mat having a weight of between 8 g/m2 and 400 g/m2,
- wherein, after melting of said first fibre thermoplast, the reinforcing fibre is oriented anisotropically in the fibre thermoplastic composite matrix, the fibre thermoplastic composite having a density of 0.25 g/cm3 to 6 g/cm3.
Dependencies are inferred from the claim text.