CN106470825A - 用于制造预成型体的干纤维带 - Google Patents
用于制造预成型体的干纤维带 Download PDFInfo
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- CN106470825A CN106470825A CN201580036021.1A CN201580036021A CN106470825A CN 106470825 A CN106470825 A CN 106470825A CN 201580036021 A CN201580036021 A CN 201580036021A CN 106470825 A CN106470825 A CN 106470825A
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- Prior art keywords
- jointing material
- preform
- band
- cross
- linking agent
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Classifications
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Abstract
在自动布置工艺例如ATL或AFP中使用的干纤维带和从其生产的预成型体。所述预成型体构造成用于树脂灌注。所述带包含单向纤维层、至少一个结合至所述纤维层的一侧的非织造遮蔽物、和在所述带中存在的至少粘合材料。从铺放此类带产生的预成型体展现出低膨松度性质，其接近于固化的经纤维增强的树脂制品的最终厚度，并且不需要进一步的固化或压实。
Description
背景
可以使用不同方法，其一个为液体成型，制造三维聚合物复合材料部件。树脂传递成型(RTM)和VARTM是涉及注射液体树脂到纤维预成型体中的制造工艺的实例。在RTM工艺期间，将预成型体放置到封闭的模腔中，并在压力下将树脂注射到所述腔中。通常将含有预成型体的模具放置在真空下，从而真空移出全部陷入预成型体中的空气并加速RTM工艺。一旦液体树脂填充所述模腔，树脂固化，导致形成复合材料部件。VARTM类似于RTM，除了将单面工具常规地与真空袋处理一起使用，并且真空将液体树脂抽到预成型体中。在很多情况下，这些技术非常适合以合理的生产率制造非常复杂形状的部件。纤维架构、预成型体和绉纹织物的渗透性、树脂粘度和操作温度对润湿织物具有影响。
为了制备所述预成型体，类似于铺放经树脂浸渍的预浸材料的方式铺放单向增强纤维或非织造织物的干层。期望将自动带铺放(ATL)和自动纤维布置(AFP)用于铺放预成型体以降低成本。然而，与适合自动布置工艺，例如ATL和AFP的干的窄宽度的纤维产品的制造相关的技术挑战需要进一步进展。
概述
本文公开了在通过自动布置工艺例如ATL或AFP纤维预成型体的制造中使用的干平带。所述带包括单向纤维层、结合至所述纤维层的一侧的至少一个非织造遮蔽物、和至少一种在所述带内存在的粘合材料。从铺放多个此类带产生的预成型体展现出低膨松度性质，其接近于固化的经纤维增强的树脂制品的最终厚度，并且不需要进一步的固化或压实。
附图的简要描述
图1为其中外部热塑性遮蔽物将外部纤维保持在一起但内部干纤维自由移动的干带的局部视图。
图2图示了根据本公开的一个实施方案的单一非织造遮蔽物粘合至一侧的经粘合剂处理的单向带。
图3图示了根据本公开的另一实施方案的非织造遮蔽物结合至相对侧的经粘合剂处理的单向带。
详细描述
在制造经纤维增强的聚合物复合材料中，由于内部缺少树脂，当与已经采用树脂浸渍的预浸渍材料相比，在纤维的放置和定向中，干纤维材料为用户提供增大的控制和操纵等级。然而，在不能将纤维固定到它们期望的位置的情况下，能够预期预成型体品质和相容性的严重问题。这在其中对于随后的灌注而言在主成型体的干组装件中预成型体需要合并处理或其中预成型体需要其他后固化操作例如准精化形状整理的情况下是特别普遍的。如果观察到纤维材料的差的压实性能，会导致严重的预成型体膨松度增加和放松的预成型体问题，则在使用干纤维材料铺放预成型体中存在重大挑战。因此，随后的预成型体处理变得更困难，因为存在层分离的风险，同时过度的膨松度会导致预成型体尺寸过大从而呈现出适应合适的工具处理的困难并可能由于在注射和固化之后纤维对树脂的低比率导致对最终的复合材料的性能障碍。
复合材料的制造商已经报道了这个过度的膨松度，其中预成型体已经引入了热塑性插页遮蔽物。其还显著影响厚度高于4mm的预成型体。
上述问题的一个解决方案是提供干带构造，其中将非织造热塑性遮蔽物层合至单向纤维带的每个面从而包封所述带并在热量和压力下使工具能够令纤维丝束(fibertows)处于适当的位置。然而，已经发现，以这种方式构造的干带通常在厚度可变性和膨松度的存在下展现出差的厚度控制。图1示出涉及这种类型的带的松散纤维的问题—热塑性遮蔽物将外部纤维保持在一起但内部干纤维自由移动。
本公开提供与常规的干单向纤维带相关的增加的厚度/膨松度问题的解决方案。本公开的一个方面是提供在自动布置中使用的干纤维带构造，从而通过铺放带产生的预成型体展现出低膨松度性质，其接近于固化的经纤维增强的树脂制品的最终厚度，并且不需要进一步的固化或压实。
本公开的一个方面涉及干平带，其包括彼此平行对齐的单向纤维层、结合至所述单向纤维层的至少一侧的非织造遮蔽物、第一粘合材料（在本文中也称为“粘合剂”），其分布在所述单向纤维层的每一侧上并穿透所述非织造遮蔽物的多个部分，或遍布所述带，包括所述单向纤维之间和遮蔽物多个部分上的空间。
根据另一实施方案，第一粘合剂分布在单向纤维层的每一侧上并穿透非织造遮蔽物的多个部分，第二粘合剂（不同于第一粘合剂）遍布所述带，包括单向纤维之间和遮蔽物多个部分上的空间。
在一些实施方案中，两个热塑性纤维的非织造遮蔽物结合至单向纤维层的相对侧。
根据一个实施方案，所述非织造遮蔽物包括纤维，其可以包括热塑性纤维和/或碳纤维。这些纤维可以随机定向或不取决于遮蔽物制造工艺条件。纤维长度可以从1/8英寸(0.32 cm)变化成2英寸(5.08 cm)长。在该实施方案中的非织造遮蔽物的面积重量优选低于10 g/m2 (gsm)。
根据另一实施方案，所述非织造遮蔽物为热塑性网格形式。可以通过挤出热塑性材料形成其中铺放热塑性材料的设计的定向网络或可控的图案而制造热塑性网格。这些方向可以为0 / ± 60，例如在同一网格内。这种类型的网格的供应商为Protechnic(France)。在本文中描述的热塑性网格的面积重量可以为2-50 gsm，优选2-20 gsm，更优选2-10 gsm的范围。
根据另一实施方案，非织造遮蔽物为具有可控图案的孔隙的多孔热塑性膜形式。作为实例，可以通过机械刺穿连续热塑性膜形成或通过常规铸造工艺形成所述多孔膜。此类膜可以包括多个微米尺寸的具有不同形状的孔隙，从而提供敞开的液体可浸入的结构。可以调节孔隙的形状和密度以提供期望的物理特性。更具体地，将孔隙构造成使在随后的树脂灌注中使用的树脂流体能够通过。多孔膜的孔隙可能采用多种形状。非限定实例包括截面为圆形、椭圆形、方形、三角形、六边形等的孔洞/开口。在膜中可以存在多于一个图案。在本文中所述的多孔膜的面积重量可以为2-50 gsm，优选2-20 gsm，更优选2-10 gsm的范围。在一些实施方案中，非织造遮蔽物由碳纤维构成。在其他实施方案中，所述非织造遮蔽物由一种或多种类型的热塑性纤维构成。或者，所述遮蔽物可以包含无机纤维和聚合物纤维的混杂物。对于热塑性纤维或多孔膜形式的非织造遮蔽物，所述热塑性材料可以选自聚酰胺、热塑性聚酰胺、脂族聚酰胺、脂环族聚酰胺、聚邻苯二甲酰胺类、聚酰胺基酰亚胺、芳族聚酰胺、聚酰亚胺、聚醚酰亚胺、聚酯、聚苯醚、聚氨酯、热塑性聚氨酯、聚缩醛、聚烯烃、热塑性聚烯烃、聚醚砜、聚醚醚砜、聚砜、聚苯砜、聚醚醚酮、聚醚酮酮、聚苯硫醚热塑性聚酰亚胺、液晶聚合物(LCP)、含苯氧基物质、丙烯酸类物质、丙烯酸酯类、其混合物或共聚物。
非织造遮蔽物（无论随机定向的纤维、网格还是多孔膜形式）的开放性对于在树脂注射或灌注工艺期间易化空气移出和树脂流动是重要的。
上文讨论的第一粘合剂和第二粘合剂都没有形成连续层。如果粘合剂在干带表面形成连续膜，则这可以防止树脂在液体成型工艺例如RTM或VARTM的树脂灌注循环期间令人满意地穿透预成型体的厚度。由此，所述带为多孔并对于在液体成型中使用的液体树脂是可渗透的。
基于干带的总重量计，在干带中的粘合剂材料的总含量为约15重量%或更低，例如0.1至15重量%，并且基于干带的总重量计，结构纤维为纤维材料的主要成分，例如大于80重量%。
在本文中公开的带可以具有最高至50英寸(1.3 m)的宽度。根据一个实施方案中，每个带具有0.1 cm至61 cm的宽度，至少为其宽度10倍的长度，和约75 µm至300 µm，包括100 µm至250 µm的厚度。
根据一个实施方案，制造干带的方法包括：施加微粒形式的第一粘合材料至铺展的单向高强度纤维（例如碳纤维）的干纤维网；结合（例如碳纤维或热塑性纤维的）非织造遮蔽物至纤维网的至少一侧；施加液体组合物形式的第二粘合材料至单向纤维/遮蔽物层合材料，例如通过浸涂；和在炉中干燥经粘合剂处理的层合材料。当施加至单向纤维时，第一粘合材料可以为颗粒形式。在替代的实施方案中，将第一粘合材料的颗粒施加至非织造遮蔽物，然后将遮蔽物粘合至纤维网。然后，将经干燥的经粘合剂处理的层合材料切割成适合ATL/AFP的窄宽度带，并且任选地，缠绕经切割的带至线轴上。
根据另一实施方案，制造干带的方法包括：施加液体形式的第一粘合材料至铺展的单向高强度纤维例如碳纤维的干纤维网，例如通过浸涂或喷涂；和在炉中干燥经粘合剂处理的单向纤维；结合（例如碳纤维或热塑性纤维的）非织造遮蔽物至纤维网的至少一侧；施加液体组合物形式的第二粘合材料至单向纤维/遮蔽物层合材料，例如通过浸涂或喷涂；和在炉中干燥经粘合剂处理的层合材料。当施加至单向纤维时，第一粘合材料可以为水乳剂形式。在替代的实施方案中，将所述第一粘合材料或者在非织造遮蔽物的制造中使用或者将其施加至非织造遮蔽物，并且然后将该遮蔽物结合至纤维网。然后，将经干燥的经粘合剂处理的层合材料切割成适合ATL/AFP的窄宽度带，并且任选地，将经切割的带缠绕到线轴上。
根据另一实施方案，已经将第一和第二粘合剂合并成一个液体形式的粘合剂。然后，制造干带的方法包括：施加液体形式的经合并的粘合剂至铺展的单向高强度纤维例如碳纤维的干纤维网，例如通过浸涂或喷涂；和在炉中干燥经粘合剂处理的单向纤维；结合（例如碳纤维或热塑性纤维的）非织造遮蔽物至纤维网的至少一侧。然后，将经干燥的经粘合剂处理的层合材料切割成适合ATL/AFP的窄宽度带，并且任选地，将经切割的带缠绕到线轴上。
可以通过自动布置工艺例如ATL或AFP通过铺放多个干带制备在液体成型工艺中使用的预成型体。已经设计膨松度测试来测定带对膨松度的影响。已经发现，当在165℃的温度下加热预成型体30秒时，该预成型体展现出低膨松度性质，从而在加热之后预成型体厚度(T2)相对于预成型体初始厚度T1 降低了1%至15% (或T2 = 0.85 T1至0.99 T1)。
在复合结构的制造中可以使用上文公开的预成型体。复合材料制造方法可以包括：
a) 通过自动布置工艺(ATL或AFP)铺放多个上述干带以形成多层预成型体，其中经固化的预成型体具有初始厚度T1；
b) 在液体成型工艺中采用液体树脂灌注所述预成型体；
c) 固化经树脂灌注的预成型体以形成具有厚度T2的复合结构。
所述预成型体在加热之后展现出低膨松度性质，由自动布置工艺的加热和成型工艺测定，并且经固化的复合结构的厚度T2降低了预成型体厚度T1的0%至10%(或0.90 T1 ≤T2 ≤ 1.00 T1)，并且在带铺放工艺之后不需要进一步的固化。
在固化之前，预成型体的变实最小（或不必要），因为随着铺放含粘合剂的带形成预成型体，在ATL/AFP工艺期间发生变实。
在一个实施方案中，所述第一粘合材料在最高至50℃的温度下为固体，具有在65℃至125℃范围的温度下的软化点，并包含环氧树脂和热塑性聚合物的共混物，但不含在高于65℃下有活性的任何催化剂或交联剂。在第一粘合材料中的热塑性聚合物可以为包含醚连接的重复单元和任选的硫醚连接的重复单元的聚芳砜聚合物，所述单元选自：
—(Ph-A-Ph)—
和任选地
— (Ph)a —
其中A为CO或SO2，Ph为亚苯基，n = 1至2并可以为小数，a = 1至4并可以为小数，条件是当a超过1时，亚苯基通过单化学键或除了—CO—或—SO2—之外的二价基团线性连接，或直接地或通过环基稠合在一起，所述环部分选自酸烷基(acid alkyl group)、（杂）芳族部分、环酮、环酰胺、酰亚胺、环亚胺和其组合。在一个实施方案中，所述热塑性聚合物为PES-PEES共聚物。制备该固体粘合材料的方法可以在受让给Cytec Technology Corp.的美国专利No. 8,927,662中发现，其内容并入本文中作为参考。
根据另一实施方案，所述第一粘合材料为多孔粘合剂分散体，其包含(a) 一种或多种多官能环氧树脂，(b) 至少一种热塑性聚合物，(c) 一种或多种选自阴离子表面活性剂和非离子表面活性剂的表面活性剂，(d) 水，和优选地，基本上不含有机溶剂。任选的添加剂例如有机或无机填料和消泡剂也可以包含在粘合剂组合物中。
在该实施方案中的热塑性聚合物在基体树脂固化之后可溶解于热固性基体树脂中。实例为如上文讨论的由醚连接的重复单元和任选的硫醚连接的重复单元构成的聚芳砜。
所述聚芳砜可以包含重复单元—(PhSO2Ph)—，其中—(PhSO2Ph)—单元以某一比例存在于聚芳砜中使得平均至少两个所述单元— (PhSO2Ph)n—依次存在于每个聚合物链中。
优选地，所述聚芳砜为包含以下单元的共聚物：
X-Ph-SO2-Ph-X-PhSO2Ph ("PES") 和 (I)
X-(Ph)a-X-PhSO2Ph ("PEES") (II)
其中X为O或S，并且在单元和单元之间可以不同，并且a为1-4。
所述热塑性聚合物可以具有2,000至30,000范围的分子量，通过高压排阻色谱法(HPSEC)测定，和高于150℃的玻璃转换温度(Tg)，通过差示扫描量热法(DSC)测定。
在该实施方案中的一种或多种表面活性剂选自：
a) 非离子表面活性剂，其为包含亲水和疏水嵌段的单或多官能嵌段或接枝嵌段共聚物；
b) 由下式表示的阴离子表面活性剂：
A—R
其中R为具有4-50个碳原子(C4至C50)的烷基、芳基、芳基-烷基、或亚烷基链；并且A为羧酸根或磺酸根或磷酸根的锂、钠、钾、铵、季铵胺盐；和
c) 非离子表面活性剂和阴离子表面活性剂的组合。
所述非离子表面活性剂包括骨架部分，疏水和亲水嵌段为骨架的一部分或基本上从骨架部分突出形成接枝或其组合。
优选地，所述非离子表面活性剂选自以下化合物：
(a) 由下式表示的Polyoxamer：
(EO)x – (PO)y – (EO)z (III)
其中x, y, z = 整数或分数，条件是(x+z)与y的比率为1.32或更高，氧化乙烯的含量为50重量%-99重量%的范围，和
其中Polyoxamer的数均分子量(Mn)为1000 g/mol -100,000 g/mol的范围，通过凝胶渗透色谱法(GPC)测定；和
(b) Polyoxamine
其中a, b, c, d, e, f, g, h为整数或分数，并且Polyoxamine的数均分子量为1000g/mol -100,000 g/mol范围。
上文讨论的液体粘合剂组合物可以进一步包含交联剂，选自氨基塑料、酚醛树脂、二氢唑酮类、氮杂环丙烷类、和嵌段的异氰酸酯。粘合剂组合物为具有40%-70%的固含量和50 nm-10000 nm范围的粒度分布的聚合物乳剂。可以通过动态光散射测定粒度分布。用于制备这种液体粘合剂组合物的方法可以在受让给Cytec Technology Corp.的美国出版物No. 2014/0179187中发现，其内容整体并入本文中作为参考。
施加聚合物乳剂的所述液体粘合剂组合物以将纤维涂布和渗透在带中。然后，根据可控时间/温度曲线蒸发水以实现期望的物理性质平衡。施加液体粘合剂组合物使其穿透所得带的结构。
在其中施加两种不同的粘合材料的实施方案中，第一粘合材料如上文所述，第二粘合材料可以为多羟基醚和聚氨酯的部分或完全交联的共聚物。在制造干带期间，可以作为基于水性分散体的液体粘合剂组合物施加第二粘合材料，所述水性分散体包含：(i) 多羟基醚和聚氨酯的共聚物，(ii) 交联剂；和任选地(iii) 催化剂。所述交联剂可以为氨基塑料交联剂，例如甲氧基烷基三聚氰胺类型的氨基塑料交联剂。所述催化剂可以包括但不限于质子给体酸，例如羧酸、磷酸、磷酸氢烷基酯(alkyl acid phosphates)、磺酸、二磺酸和/或路易斯酸例如氯化铝、溴化铝或卤化铝、卤化铁、三卤化硼，和本领域技术人员熟知的这两种类别的很多其他物质。
根据另一实施方案，第二粘合材料为聚氨酯或改性的聚氨酯聚合物。在干带制造期间，可以作为基于水性分散体的液体粘合剂组合物施加第二粘合材料，所述水性分散体包含：(i) 聚氨酯；和(ii) 任选地，交联剂。由此，制造的带可以包含非交联的、部分或完全交联的聚氨酯聚合物。
可以通过多异氰酸酯与数均摩尔质量(Mn)为至少400 g/mol（通过GPC测定）的一种或多种多元醇反应合成聚氨酯，所述多元醇选自脂族或芳族聚醚多元醇和聚酯多元醇并任选地：
能够形成阴离子并具有至少两个对异氰酸根有反应性的基团的化合物；
Mn为60至400 g/mol的低摩尔质量多元醇；
其组合。
用于制备聚氨酯的合适的多异氰酸酯（其是指具有多个异氰酸根的化合物）包括任何有机多异氰酸酯，优选单体二异氰酸酯。特别优选的是多异氰酸酯，特别是具有脂族-和/或脂环族-连接的异氰酸根的二异氰酸酯，不过不排除具有芳族-连接的异氰酸根的多异氰酸酯并且也可以使用。
可以使用的合适的多异氰酸酯的实例包括亚乙基二异氰酸酯、1,4-四亚甲基二异氰酸酯、1,6-六亚甲基二异氰酸酯、2,4,4- 三甲基-1,6-六亚甲基二异氰酸酯、1,12-十二烷二异氰酸酯、环丁烷-1,3-二异氰酸酯、环己烷-1,3-和/或-1,4-二异氰酸酯、1-异氰酸根合-2-异氰酸根合甲基环戊烷、1-异氰酸根合-3,3,5-三甲基-5-异氰酸根合甲基环己烷(异佛尔酮二异氰酸酯或IPDI)、2,4-和/或2,6-六氢亚甲苯基二异氰酸酯、2,4'- 和/或 4,4'-二环己基甲烷二异氰酸酯、a,a,a',a-四甲基-1,3-和/或-1,4-亚二甲苯基二异氰酸酯、1,3-和1,4-亚二甲苯基二异氰酸酯、1-异氰酸根合-1-甲基-4(3)-异氰酸根合甲基环己烷、1,3-和1,4-亚苯基二异氰酸酯、2,4-和/或 2,6-亚甲苯基二异氰酸酯、二苯基甲烷-2,4'-和/或-4,4'-二异氰酸酯、萘-1,5-二异氰酸酯、三苯基甲烷-4,4',4"-三异氰酸酯、通过苯胺与甲醛缩合然后光气化获得的类型的多苯基多亚甲基多异氰酸酯、和上述多异氰酸酯的混合物。
合适的多元醇优选的数均摩尔质量(Mn)为400 g/mol至5000 g/mol。合适的多元醇的实例包括脂族聚醚多元醇，例如聚氧基亚乙基二醇、聚氧基亚丙基二醇、或此类单元的混合聚合物；可通过二醇或多元醇与二羧酸或多羧酸的缩聚获得的聚酯多元醇，此类聚酯多元醇包括聚己二酸亚乙酯；衍生自乙二醇、己二醇、三羟甲基丙烷、己二酸和对苯二甲酸的混合聚酯等。可以构造此类聚酯多元醇或包括在此类聚酯多元醇中的其他构筑嵌段为羟基羧酸，例如羟基丁酸或羟基己酸或它们的内酯。
合适的芳族聚醚多元醇为环氧树脂或苯氧树脂，或其混合物。
能够形成阴离子的化合物的实例包括多元醇，特别是二醇，和多胺，特别是二胺，或羟胺，其中每个分子携带1至3个羧基或磺酸基。
能够形成阴离子的化合物的实例包括多元醇，特别是二醇，和多胺，特别是二胺，或羟胺，其中每个分子携带1至3个羧基或磺酸基。
该组合物的含羧酸根的化合物的实例包括异氰酸根封端的多元醇预聚物（通过过量的二异氰酸酯与含羟基预聚物的反应获得）与含羟基的羧酸的反应。本发明的阳离子封端的化合物的实例包括季铵或鏻预聚物。此类阳离子组合物可以通过含叔胺的醇与上述异氰酸根封端的预聚物的反应然后与季化剂例如本领域技术人员已知的硫酸二甲酯或烷基卤化物的反应制备。具有优选60至400的摩尔质量的低摩尔质量多元醇的实例包括乙二醇、二乙二醇、1,4-丁二醇、环己二醇和本领域技术人员已知的任何其他二醇。
用于聚氨酯的合适的交联剂可以包括但不限于二异氰酸酯或多异氰酸酯交联剂，例如脂族或芳族多异氰酸酯交联剂。
多异氰酸酯交联剂的实例为由BASF采用商标Perapret Booster XLR或由Bayer采用商标Desmodur® N商品化的改性的脂族多异氰酸酯。芳族多异氰酸酯的实例为由Bayer采用商标Desmodur® L商品化的基于甲苯二异氰酸酯 (TDI)的多异氰酸酯。
在另一实施方案中，第二粘合材料包括环氧树脂或改性环氧树脂。
在制造干带期间，可以作为基于水性分散体的液体粘合剂组合物施加第二粘合材料，所述水性分散体包含：(i) 环氧树脂；和(ii) 任选地，交联剂。由此，制造的带可以包含非交联的、部分或完全交联的环氧树脂。
环氧树脂的实例为每个分子具有至少两个环氧基团的那些，并具有优选聚醚结构，其转而具有衍生自1, 2, 3-三羟基丙烷的部分和衍生自芳族二羟基或多羟基化合物的部分。一般而言，聚环氧化物每个分子平均具有至少两个环氧基团。所述环氧化合物可以为脂族、脂环族、芳族或杂环的并还可以包含羟基。
优选地，这些环氧化合物为基于多羟基、优选二羟基醇、多羟基、优选二羟基酚、所述酚的氢化产物、酚醛清漆和/或苯胺的聚缩水甘油醚。
作为多羟基酚，它们可以包括例如间苯二酚、氢醌、2,2-双(4-羟基苯基)丙烷(双酚A)、二羟基二苯基甲烷(双酚F)的异构混合物、四溴双酚A、4,4'-二羟基二苯基环己烷、4,4'-二羟基-3,3'-二甲基二苯基丙烷、4,4'-二羟基联苯, 4,4'-二羟基二苯甲酮、双(4-羟基苯基)-l,l-乙烷、双(4-羟基苯基)-l,l-异丁烷、双(4-羟基-叔丁基苯基)-2,2-丙烷、双(2-羟基萘基)甲烷、l,S-二羟基萘、三(4-羟基苯基)甲烷、双(4-羟基苯基)醚、和双(4-羟基苯基)砜、和上述化合物的氯化和溴化产物。双酚A是特别优选的。
多羟基醇的聚缩水甘油醚作为环氧树脂也是适合的。作为此类多羟基醇的实例，它们可以包括乙二醇、二乙二醇、三乙二醇、1,2-丙二醇、聚氧基亚丙基二醇（具有二至十个1,2-亚丙基氧基单元）、1,3-丙二醇、1,4-丁二醇、1,S-戊二醇、1,6-己二醇、1,2,6-己三醇、甘油、和双(4-羟基环己基)-2,2-丙烷。
合适的树脂还包括芳族缩水甘油基胺环氧树脂，例如芳族多胺例如苯胺、二氨基二苯基甲烷、邻-、对-、间-氨基苯酚、2-氨基-对甲酚、6-氨基-对甲酚、邻-、对-、间-亚二甲苯基二胺、邻-、间-、对-氯苯胺、邻-、间-、对-溴苯胺、邻-、间-、对-碘苯胺、双氨基甲基环己烷与表氯醇的缩合物。
还可以使用多羧酸的聚缩水甘油酯，其通过表氯醇或类似的环氧化合物与脂族、脂环族或芳族多羧酸，例如草酸、琥珀酸、己二酸、戊二酸、邻苯二甲酸、对苯二甲酸、六氢邻苯二甲酸、2,6-萘二甲酸和二聚化亚麻酸的反应获得。实例为己二酸二缩水甘油酯、邻苯二甲酸二缩水甘油酯和六氢邻苯二甲酸二缩水甘油酯、酯环氧树脂例如（甲基）丙烯酸缩水甘油酯与烯属不饱和单体例如丙烯腈、羟基（甲基）丙烯酸酯、N, N '-二甲基氨基乙基（甲基）丙烯酸酯的共聚物；环氧树脂例如环氧豆油。合适的环氧化合物的详细列举可以在由McGraw-Hili Brook Company在1967年公开的Henry's Handbook of Epoxy Resins第1-1至3-20页和在Lee and Neville "Handbook of Epoxy Resins", 1967, 第2章找到。还可以预期所述的几种环氧化合物的混合物。
用于环氧树脂的合适的交联剂可以包括但不限于每个氨基具有最高达500的分子量的氨基化合物，例如芳胺或胍衍生物。具体实例为3,3'-和4-,4'-二氨基二苯基砜(DDS)；亚甲基二苯胺；双(4-氨基-3,5-二甲基苯基)-1,4-二异丙基苯; 双(4-氨基苯基)-1,4-二异丙基苯；4,4’亚甲基双-(2,6-二乙基)-苯胺 (MDEA; Lonza)；4,4’亚甲基双-(3-氯, 2,6-二乙基)-苯胺 (MCDEA; Lonza)；4,4’亚甲基双-(2,6-二异丙基)-苯胺 (M-DIPA;Lonza)；3,5-二乙基甲苯-2,4/2,6-二胺(D-ETDA 80; Lonza)；4,4’亚甲基双-(2-异丙基-6-甲基)-苯胺 (M-MIPA; Lonza)；4-氯苯基-N,N-二甲基-脲(例如Monuron)；3,4-二氯苯基-N,N-二甲基-脲(例如DiuronTM)和二氰基二酰胺 (AmicureTM CG 1200; PacificAnchor Chemical)。双酚扩链剂，例如双酚-S或硫代双酚，也可作为固化剂用于环氧树脂。合适的固化剂还包括：i) 酸酐特别是多羧酸酸酐，例如NA酸酐、甲基NA酸酐、邻苯二甲酸酐、四氢邻苯二甲酸酐、六氢邻苯二甲酸酐、甲基四氢邻苯二甲酸酐、降冰片烯二酸酐、或偏苯三甲酸酐；ii) 氨基树脂交联剂，例如甲基化和丁基化三聚氰胺、烷基化和亚胺基混合的醚三聚氰胺、烷基化脲、苯并胍胺和甘脲；iii) 酚醛塑料；iv) 二氢唑酮类；和v) 氮杂环丙烷类。
一种或多种催化剂还可以用于加速固化反应。合适的催化剂也是本领域中熟知的，并包括强酸例如超强酸和其保护的形式(blocked versions)、路易斯酸或碱。特定实例包括包含三氟化硼，例如其醚合物或胺加合物（例如三氟化硼与乙胺的加合物）的组合物，特别是其中环氧树脂前体与上述胺固化剂一起使用。
在另一实施方案中，第二粘合材料包括多羟基醚或“苯氧”树脂。在制造干带期间，可以作为基于水性分散体的液体粘合剂组合物施加第二粘合材料，所述水性分散体包含：(i) 苯氧树脂；和(ii) 任选地，交联剂。因此，所制造的带可以包含非交联、部分或完全交联的苯氧树脂。
所述聚(羟基醚)树脂具有通式：
其中D为二羟基酚的残基，E为环氧化物的含羟基的残基，n代表聚合度并且为至少30，优选80或更大。术语“热塑性聚(羟基醚)”意在包括至少两种热塑性聚(羟基醚)的混合物。
提供酚残基D的二羟基酚，可以为二羟基单核或二羟基多核酚，例如具有以下通式的那些：
其中Ar为芳族二价烃例如亚萘基，优选亚苯基，可以相同或不同的X和Y为优选具有1至4个碳原子的烷基、卤素原子，即氟、氯、溴和碘，或优选具有1至4个碳原子的烷氧基，a和b为0至最大值的整数值，所述最大值对应于在可以被取代基取代的芳基(Ar)上的氢原子数，R为相邻碳原子，如在二羟基二苯基之间的键，或为二价基团，包括例如
和二价烃基，例如亚烷基、烷叉基、脂环族，例如环烷叉基、卤代烷氧基或芳氧基取代的亚烷基、烷叉基和脂环族基团和亚烷芳基和芳族基团包括卤素、烷基、烷氧基或芳氧基取代的芳族基团和稠合至Ar基团的环；或R可以为被芳环、叔氨基、醚键、羰基或含硫基例如亚砜等分开的多烷氧基或多硅氧基、或两个或更多个烷叉基。
特定的二羟基多核酚的实例包括：
双(羟基苯基)烷烃例如2,2-双-(4-羟基苯酚)丙烷、2.4'-二羟基二苯基甲烷、双(2-羟基苯基)甲烷、双(4-羟基苯基)甲烷、双(4-羟基-2,6-二甲基-3-甲氧基苯基)甲烷、l,l-双(4-羟基苯基乙烷、l,2-双(4-羟基苯基)-乙烷、1,1-双(4-羟基-2-氯苯基)乙烷、1,1-双-(3-甲基-4-羟基苯基)乙烷、1,3-双(3-甲基-4-羟基苯基)丙烷、2,2-双(3-苯基-4-羟基苯基)-丙烷、2,2-双(3-异丙基-4-羟基苯基)丙烷、2,2-双(2-异丙基-4-羟基苯基)丙烷、2,2-双-(4-羟基萘基)丙烷、2,2-双(4-羟基苯基)-戊烷、3,3-双(4-羟基苯基)戊烷、2,2-双(4-羟基苯基)庚烷、双(4-羟基苯基)苯基甲烷、双(4-羟基苯基)环己基甲烷、1,2-双(4-羟基-苯基-1,2-双(苯基)丙烷、2,2,-双(4-羟基苯基)-l-苯基-丙烷等；
二(羟基苯基)砜例如双(4-羟基-苯基)砜、2,4'-二羟基二苯基砜、5'-氯-2,4'-二羟基二苯基砜、5'-氯-4,4'-二羟基二苯基砜等；
二(羟基苯基)醚，例如双(4-羟基-苯基)醚、4,3'-, 4,2'-, 2,2'-, 2,3'-, 二-羟基二苯基醚、4,4'-二羟基-2,6-二甲基二苯基醚、双(4羟基-3-异丁基苯基)醚、双(4-羟基-3-异丙基苯基)醚、双(4-羟基-3-氯苯基)-醚、双(4-羟基-3-氟苯基)醚、双(4-羟基-3-溴苯基)醚、双(4-羟基萘基)醚、双(4-羟基-3-氯萘基醚、双(2-羟基二苯基)-醚、4,4'-二羟基-2,6-二甲氧基二苯基醚、4,4-二羟基-2,5-二乙氧基二苯基醚等。
替代的合适的二羟基多核酚为4-乙烯基环己烯和酚的双酚反应产物，例如1,3-双(对羟基苯基)-1-乙基环己烷和二戊烯或其异构体与酚的双酚反应产物，例如l,2-双(对羟基苯基)-l-甲基-4-异丙基环己烷，以及双酚例如1,3,3'三甲基-1-(4-羟基苯基)-6-羟基茚满和2,4-双(4-羟基苯基)-4-甲基戊烷等。
其中X和Y如上文定义，a和b具有0至4的值，包括边界值，R为具有1至3个碳原子的二价饱和脂族烃基，特别是亚烷基和烷叉基，和具有最多和包括10个碳原子的亚环烷基。
还可以使用二羟基酚的混合物，并且无论何时在本文中使用术语“二羟基酚”或“二羟基多核酚”，都意在包括这些化合物的混合物。
提供含羟基的残基E的环氧化物可以为单环氧化物或二环氧化物。单环氧化物包含一个此类环氧乙烷基团并提供包含一个羟基的残基E，二环氧化物包含两个此类环氧乙烷基团并提供包含两个羟基的残基E。饱和环氧化物，该术语是指不含烯属不饱和度，即> C- C <和炔属不饱和度，即-C≡C-的二环氧化物，是优选的。特别优选的是卤素取代的饱和单环氧化物即表氯醇，和只包含碳、氢和氧的饱和二环氧化物，特别是其中邻近或相邻碳原子形成脂族烃链的一部分的那些。除了环氧乙烷氧之外，在此类二环氧化物中的氧可以为醚氧-O-、氧杂羰基氧(oxacarbonyl oxygen)、羰基氧等。
单环氧化物的特定实例包括表氯醇类，例如表氯醇、表溴醇、l,2-环氧基-1-甲基-3-氯丙烷、l,2-环氧基-l-丁基-3-氯丙烷、1,2-环氧基-2-甲基-3-氟丙烷等。
示例性的二环氧化物包括二乙二醇双(3,4-环氧基环己烷-甲酸酯)、双(3,4-环氧基环己基-甲基)己二酸酯、双(3,4-环氧基环己基-甲基)邻苯二甲酸酯、6-甲基-3,4-环氧基环己基甲基-6-甲基-3,4-环氧基环己烷甲酸酯、2-氯-3,4-环氧基环己基甲基-2-氯-3,4-环氧基环己烷-甲酸酯、二缩水甘油醚、双(2,3-环氧基环戊基)-醚、1,5-戊二醇双(4-甲基-3,4-环氧基环己基-甲基)醚、双(2,3-环氧基-2-乙基己基)己二酸酯、马来酸二缩水甘油酯、邻苯二甲酸二缩水甘油酯、3-氧杂-四环[4.4.0.17,10.02,4]-十一烷-8-基 2,3-环氧基-丙基醚、双(2,3-环氧基环戊基)砜、双(3,4-环氧基己氧基)砜、2,2'-磺酰基二乙基、双(2,3-环氧基环戊烷-甲酸酯)、3-氧杂四环-[4.4.0.1 7,10.02,4]-十一烷-8-基 2,3-环氧基丁酸酯、4-戊烯醛-缩二-(6-甲基-3,4-环氧基环己基甲醇)、乙二醇双(9,10-环氧基硬脂酸酯)、碳酸二缩水甘油酯、双(2,3-环氧基丁基苯基)-2-乙基己基磷酸酯、二环氧基二氧六环、丁二烯二氧化物和2,3-二甲基丁二烯二氧化物。
优选的水性苯氧树脂的实例为具有以下结构式的衍生自双酚-A (2,2-双(对羟基苯基)丙烷和表氯醇的缩聚物：
用于苯氧树脂的合适的交联剂的实例包括异氰酸酯、酸酐、三嗪和三聚氰胺。
合适的交联剂包括氨基塑料或氨基树脂交联剂，其为脲或三聚氰胺与甲醛和醇的反应产物。除了脲和三聚氰胺之外，还可以使用具有类似官能团的那些化合物例如苯并胍胺、甘脲、环脲、乙内酰脲类、伯和仲酰胺、氨基甲酸酯等，其中需要某些性质优势。
可以施加聚合物乳剂形式的上文讨论的液体苯氧基粘合剂组合物以涂布和渗透纤维在带中。然后，根据可控时间/温度曲线蒸发水以实现期望的物理性质平衡。施加液体粘合剂组合物从而其穿透所得带的结构。
图2图示了根据本公开的一个实施方案的干带，其中将单一非织造遮蔽物结合至单向纤维（例如碳纤维）层的一侧。图3示出其中单向纤维夹在两个非织造遮蔽物之间的实施方案。第一粘合材料保留在带的外表面，而第二粘合剂穿透带的厚度。每种粘合剂都具有特定益处。第一粘合剂给予遮蔽物与单向纤维的粘合和带在制造期间的凝聚力和稳定性并提供经切割的带宽度的非常好的控制。其还通过粘合经切割的带至工具或先前铺放的层提供有效的铺放工艺和预成型体制备工艺。
第二粘合剂将带的单向纤维长丝彼此保持在一起。结果，其改善经切割的带的耐磨性和耐起毛性，其转而提供经切割的带宽度的更好的控制。在ATL/AFP铺放工艺期间，其还提高经切割的带的硬度，导致获得改善的处理。并且，由于长丝结合在一起，第二粘合材料还促进干带和制成的预成型体的较低的膨松度。
当干带仅包含结合至单向纤维层的相对侧的热塑性遮蔽物而没有任何粘合材料时，观察到“回弹”效果。所述干带床表现得像弹簧，并示范了厚度松弛和差的总预成型体稳定性，特别是在厚度大于4 mm的厚铺放物的情况下。第一和第二粘合材料的存在负面影响弹回效果。
据信本文中公开的粘合剂的组合促进通过铺放干带形成的预成型体的低膨松度，因为它们保持预成型体的叠覆层粘合在一起。
本文中公开的粘合剂的组合帮助在用于形成预成型体的带铺放工艺期间使单向结构纤维稳定，但不干扰树脂灌注工艺和最终复合材料部件的机械性能。非织造遮蔽物在树脂注射循环期间提高面内树脂扩散。作为附加的益处，遮蔽物，其位于具有结构纤维和高度负载有树脂的层之间的层间区域，可以充当用于进一步增韧所得复合材料的材料例如增韧颗粒或增韧纤维的载体。
本文中公开的干平带为自支撑纤维材料。本文中使用的术语“干”是指可以被认为具有干感的材料，其接触起来不会发粘并且除了上文公开的粘合剂之外基本上没有任何基体树脂。术语“自支撑”是指彼此不分开的纤维或长丝的紧密结合形式，例如在切割工艺和其他随后处理期间，例如在纤维产品通过自动化机器处理时。此外，可以在室温下储存干的经粘合剂处理的带，并且由于其不含大量基体树脂的事实，相比于预浸材料，不需要冷冻。
在干带中的单向纤维为适合高强度复合材料的结构增强的高强度纤维。至此，单向纤维可以从高强度材料例如碳、石墨、玻璃和芳族聚酰胺制备。
非织造遮蔽物为可以包含另外的粘合或增韧剂/颗粒的轻质材料。非织造遮蔽物的存在改善带的面内渗透性并且有利于面内树脂流动。此外，遮蔽物为单相纤维层提供另外的稳定性。遮蔽物的进一步的益处为其可以在层间区域用作复合增韧颗粒、纤维、纳米颗粒或其他填料例如膨胀剂、阻燃剂的载体。
在本文中公开的粘合材料促进干带的低膨松度性质。当使用聚合物非织造遮蔽物时，聚合物遮蔽物和粘合剂的优选软化点为160℃或更低（通过差示扫描量热法测定）从而使带能够结合并以可接受的机械速度形成固化的预成型体。
实施例
如表1中所示，在采用或不采用粘合剂的情况下制备六种不同类型的干带。每个带具有结合至单向碳纤维层的一侧或两侧的共聚酰胺纤维(BR8 from Protechnic, France)的非织造尼龙遮蔽物，其中所述遮蔽物具有6 gsm的面积重量和约155℃的软化点（通过差示扫描量热法使用以5℃/min升温速率从50℃至350℃的温度斜升试验来测试）。粘合剂1包含环氧树脂和PES-PEES共聚物的共混物，并且如果施加的话，存在于单向纤维层的顶部和底部表面上。粘合剂2包含多羟基醚和聚氨酯的共聚物，并且如果施加的话，遍布所述带而存在。以微粒形式施加粘合剂1并以乳剂形式施加粘合剂2。
表1 - 具有热塑性遮蔽物的干带
| 带ID | 热塑性遮蔽物 [BR8] | 粘合剂1 | 粘合剂2 |
| 1A | 底部 | 无 | 无 |
| 1B | 底部 | 顶部&底部 | 无 |
| 2A | 顶部&底部 | 无 | 无 |
| 2B | 顶部&底部 | 无 | 有 |
| 3A | 顶部&底部 | 顶部&底部 | 无 |
| 3B | 顶部&底部 | 顶部&底部 | 有 |
制造具有粘合至单向纤维的非织造碳遮蔽物而非尼龙遮蔽物的另一干带。表2概括了带结构。该带具有结合至单向碳纤维的一侧的碳纤维的非织造遮蔽物并包含粘合剂1和2。
表2 - 具有碳遮蔽物的干带
| 带ID | 碳遮蔽物 | 粘合剂1 | 粘合剂2 |
| 4 | 底部 | 有 | 有 |
使用表1和表2中示出的干带筑造顺序为[+45/0/-45/90]的24层的预成型体堆叠物。然后，对预成型体堆叠物进行真空袋处理并在130℃或165℃下暴露15分钟和在165℃下暴露30秒，从而看见温度对预成型体膨松度的影响。相对于尼龙遮蔽物的熔点（即155℃）选择温度。带在165℃下暴露30秒与典型的ATL/AFP处理条件更一致。一旦完成热循环，在真空下冷却预成型体。采用测微计进行厚度测试并根据位置（纵向网和交叉网）的取样收集，每个位置测试一次。在表3A和3B中概括了结果。
如前文所述，165℃/30 s条件为自动纤维布置工艺(AFP)的代表，其中特别地，材料对热量的短时间暴露是由于AFP工艺的性质，同时调节热量以使铺放的材料发粘。注意到15分钟的加热时间不是AFP工艺而是手工铺放压实工艺的代表。然后，在这些条件下构筑的预成型体的厚度可与期望的复合材料的目标固化层厚(cpt)比较。下文的公式1可以用于推演出复合材料的cpt，条件是每层的复合纤维体积分数、纤维密度和纤维面积重量都是已知的。
公式1：
其中cpt = 固化层厚 (mm)
Fd = 纤维密度(g/cm3)
FVF = 复合纤维体积分数
FAW = 纤维面积重量(g/m2)
下表4提供每种材料的cpt和预成型体阶段和固化的复合材料阶段之间的膨松度变化。在表4中提供每种材料的纤维密度和纤维面积重量，并根据公式1推演出cpt，其中采用57%的纤维体积分数，其对于这种类型的复合材料和这种类型的复合材料制造工艺即AFP和树脂灌注是现实目标。
表4的最后一列提供从预成型体阶段到固化的复合材料阶段的膨松度变化，并且可以看出基于带2A的材料具有最高水平的变实度(12.5%)。带2A不含粘合剂1或粘合剂2。在比较中，材料3B和4具有最低的变实性能，两者都采用包含粘合剂1和2的带制造。材料3A的变实度大致为材料2A的一半。这由于添加粘合剂1至带2A而实现。
尽管材料1A实现了从预成型体至复合材料的低变实性能，但该材料实际上是不可行的，因为其不稳定并且不能用于自动工艺或甚至手动铺放方式。然而，由于使用了单一热塑性遮蔽物与两个热塑性遮蔽物的比较，确实突出了对预成型体膨松度的影响。具有两个热塑性遮蔽物的材料在AFP机器中是可操作的但获得比含有粘合剂1和2两者的材料更高的膨松度。
由此，具有粘合剂1和2的益处已经清楚地示范在这些实施例中。根据经验，认为最高至10 %最大值的变实度（即膨松度的降低）将遭遇变实的问题例如工具设计、预成型体毁坏等最小化。并且，随着预成型体厚度生长至10 mm或甚至20 mm的尺寸—在上文实施例中其为约5 mm的层合材料—时，对膨松度的影响变得甚至更重要并且技术人员能够预期预成型体与固化的复合材料部件之间的厚度差会增加，这使得更期望使用粘合剂1和2控制预成型体膨松度。对于厚复合材料部件，材料2A是不可接受的命题，而材料3B和4，其包含粘合剂1和2以保持低膨松度成型体，是有利的。
Claims (23)
1.构造成在液体成型工艺中接收液体树脂的预成型体，所述预成型体具有初始厚度T1并包括多个通过自动布置工艺铺放的叠覆纤维带，
其中
每个带包括彼此平行对齐的单向纤维层、结合至所述单向纤维层的至少一侧的非织造遮蔽物、和至少一种粘合材料，该粘合材料分布在所述单向纤维层的至少一侧上并穿透所述非织造遮蔽物的多个部分，或遍布所述带，包括所述单向纤维之间和所述遮蔽物的多个部分上的空间，
所述粘合材料选自：
i. 粘合剂，其在最高至50℃的温度下为固体，软化点为75℃至125℃范围的温度，其通过差示扫描量热法(DSC)测定，并包含环氧树脂和热塑性聚合物的共混物，但不含在高于75℃下有活性的任何催化剂或交联剂；
ii. 组合物，其包含至少一种多官能环氧树脂；至少一种热塑性聚合物；和至少一种选自阴离子表面活性剂和非离子表面活性剂的表面活性剂；
iii. 部分或完全交联的多羟基醚和聚氨酯的共聚物；
iv. 聚氨酯，其为非交联的、部分或完全交联的、或改性的聚氨酯聚合物；
v. 环氧化物，其为非交联的、部分或完全交联的、或改性的环氧化物；和
vi. 聚(羟基醚)树脂，其为非交联的、部分或完全交联的；
包括所述非织造遮蔽物的所述带为多孔和对液体树脂为渗透性的从而用于随后的液体成型工艺中；和
所述预成型体在加热之后展现出低膨松度性质，其通过自动布置工艺的加热和成型工艺测定。
2.权利要求1所述的预成型体，其中当采用树脂灌注预成型体并然后固化形成复合结构时，该复合结构的固化厚度T2降低了预成型体初始厚度T1的0%至10% （或0.90 T1 ≤ T2≤ 1.00 T1）并且在所述带铺放工艺之后不需要进一步固化。
3.权利要求1或2所述的预成型体，其中在粘合材料(i)或(ii)中的热塑性聚合物为包含醚连接的重复单元和任选硫醚连接的重复单元的聚芳砜聚合物，所述单元选自：
—(Ph-A-Ph)—
和任选
— (Ph)a —
其中A为CO或SO2，Ph为亚苯基，n = 1至2并可以为小数，a = 1至4并可以为小数，条件是当a超过1时，亚苯基通过单化学键或除了—CO—或—SO2—之外的二价基团线性连接，或直接地或通过环基稠合在一起，所述环部分选自酸烷基、（杂）芳族部分、环酮、环酰胺、酰亚胺、环亚胺和其组合。
4.根据前述权利要求任一项所述的预成型体，其中所述粘合材料(ii)中的表面活性剂选自：
a）非离子表面活性剂，其为包含亲水和疏水嵌段的单或多官能嵌段或接枝嵌段共聚物；
b）阴离子表面活性剂，其由下式表示：
A—R
其中R为具有4-50个碳原子(C4至C50)的烷基、芳基、芳基-烷基、或亚烷基链；和A为羧酸根、磺酸根、或磷酸根的锂、钠、钾、铵、季铵胺盐；和
c）非离子表面活性剂和阴离子表面活性剂的组合。
5.根据前述权利要求任一项所述的预成型体，其中每个带包括两种不同的粘合材料，
第一粘合材料为粘合材料(i)或(ii)，和
第二粘合材料选自材料(iii)至(vi)。
6.根据权利要求5所述的预成型体，其中所述第一粘合材料为材料(i)。
7.根据权利要求5所述的预成型体，其中所述第一粘合材料为材料(ii)。
8.根据权利要求6或7所述的预成型体，其中所述第二粘合材料为材料(iii)。
9.根据前述权利要求任一项所述的预成型体，其中所述带的非织造遮蔽物为随机定向的纤维；以某种图案（包括网格图案）的定向纤维；或多孔膜的形式。
10.根据前述权利要求任一项所述的预成型体，其中每个带包括结合至单向纤维层的相对侧的两个热塑性纤维的非织造遮蔽物。
11.根据前述权利要求任一项所述的预成型体，其中每个带包括结合至单向纤维层的一侧的一个碳纤维的非织造遮蔽物。
12.根据前述权利要求任一项所述的预成型体，其中每个带的宽度为0.1 cm至61 cm，长度为其宽度的至少10倍，和厚度为约75 µm至300 µm或100 µm至250 µm。
13.根据前述权利要求任一项所述的预成型体，其中所述一种或多种粘合材料以足以保持纤维和非织造遮蔽物在一起的量存在，但基于所述带的总重量计，一种或多种粘合材料的总量低于15 %。
14.制造复合结构的方法，其包括：
a) 通过自动布置工艺铺放多个干纤维带以形成具有初始厚度T1的多层预成型体，每个带包括：彼此平行对齐的单向纤维层、至少一个结合至所述单向纤维层的一侧的非织造遮蔽物、和至少一种粘合材料，该粘合材料分布在所述单向纤维层的至少一侧上并穿透所述非织造遮蔽物的多个部分，或遍布所述带，包括所述单向纤维之间和所述非织造遮蔽物的多个部分上的空间，和
b) 在液体成型工艺中采用液体树脂灌注所述预成型体；
c) 固化经树脂-灌注的预成型体以形成复合结构，
其中所述预成型体在加热之后展现出低膨松度性质，其通过自动布置工艺的加热和成型工艺测定，并且该复合结构的固化厚度T2降低了预成型体初始厚度T1的0%至10%（或0.90T1 ≤ T2 ≤ 1.00 T1）并且在所述带铺放步骤(a)之后不需要进一步固化；和
其中所述粘合材料选自：
i. 粘合剂，其在最高至50℃的温度下为固体，软化点为75℃至125℃范围的温度，其通过DSC测量，并包含环氧树脂和热塑性聚合物的共混物，但不含在高于75℃下有活性的任何催化剂或交联剂；和
ii. 组合物，其包含至少一种多官能环氧树脂；至少一种热塑性聚合物；和至少一种选自阴离子表面活性剂和非离子表面活性剂的表面活性剂；
iii. 部分或完全交联的多羟基醚和聚氨酯的共聚物；
iv. 聚氨酯，其为非交联的、部分或完全交联的、或改性的聚氨酯聚合物；
v. 环氧化物，其为非交联的、部分或完全交联的、或改性的环氧化物；和
vi. 聚(羟基醚)树脂，其为非交联的、部分或完全交联的。
15.权利要求14所述的方法，其中所述粘合材料(i)或(ii)中的热塑性聚合物为聚芳砜聚合物。
16.权利要求14或15所述的方法，其中所述粘合材料(ii)中的表面活性剂选自：
a) 非离子表面活性剂，其为包含亲水和疏水嵌段的单或多官能嵌段或接枝嵌段共聚物；
b) 由下式表示的阴离子表面活性剂：
A—R
其中R为具有4-50个碳原子(C4至C50)的烷基、芳基、芳基-烷基、或亚烷基链；和A为羧酸根或磺酸根或磷酸根的锂、钠、钾、铵、季铵胺盐；和
c) 非离子表面活性剂和阴离子表面活性剂的组合。
17.根据权利要求14至16任一项所述的方法，其中每个带包含两种不同的粘合材料，
第一粘合材料为粘合材料(i)或(ii)，和
第二粘合材料选自材料(iii)至(vi)。
18.根据权利要求14至17任一项所述的方法，其中每个带包含结合至单向纤维层的一侧的非织造遮蔽物，其中所述非织造遮蔽物为随机排列的纤维、以某种图案的定向纤维、或多孔膜的形式。
19.根据权利要求14至18任一项所述的方法，其中每个带包括结合至单向纤维层的相对侧的两个热塑性纤维的非织造遮蔽物或结合至单向纤维层的一侧的至少一个碳纤维的非织造遮蔽物。
20.制造用于自动带铺放的干纤维带的方法，所述方法包括：
施加微粒形式的第一粘合材料至铺展的单向纤维的干纤维网；
结合非织造遮蔽物至所述纤维网的至少一侧以形成层合材料；
施加液体组合物形式的第二粘合材料至所述层合材料，从而形成经粘合剂处理的层合材料；
干燥所述经粘合剂处理的层合材料；和
切割经干燥的层合材料以形成适合自动带铺放的带，
其中第一粘合材料不同于第二粘合材料，并且在最高至50℃的温度下为固体，软化点为75℃至125℃范围的温度，其通过DSC测量，并包含环氧树脂和热塑性聚合物的共混物，但不含在高于75℃下有活性的任何催化剂或交联剂；和
其中所述第二粘合材料为包含至少一种以下物质的水性分散体：
i. 多羟基醚和聚氨酯的共聚物，氨基塑料交联剂；和任选地，催化剂；
ii. 聚氨酯，和任选地，交联剂；
iii. 环氧树脂，和任选地，交联剂；和
iv. 苯氧树脂；和任选地，交联剂。
21.制造用于自动带铺放的干纤维带的方法，所述方法包括：
施加液体组合物形式的第一粘合材料至铺展的单向纤维的干纤维网；
干燥经粘合剂处理的遮蔽物；
结合非织造遮蔽物至铺展的单向纤维的纤维网的至少一侧以形成层合材料；
施加液体组合物形式的第二粘合材料至层合材料，从而形成经粘合剂处理的层合材料；
干燥经粘合剂处理的层合材料；和
切割经干燥的层合材料以形成具有在适合自动带铺放的范围内的窄宽度的带，
其中第一粘合材料为包含至少一种多官能环氧树脂、至少一种热塑性聚合物、和至少一种选自阴离子表面活性剂和非离子表面活性剂的表面活性剂的液体组合物，和
其中第二粘合材料为包含至少一种以下物质的水性分散体：
i. 多羟基醚和聚氨酯的共聚物，氨基塑料交联剂；和任选地，催化剂；
ii. 聚氨酯，和任选地，交联剂；
iii. 环氧树脂，和任选地，交联剂；和
iv. 苯氧树脂；和任选地，交联剂。
22.制造用于自动带铺放的干纤维带的方法，所述方法包括：
施加包含第一粘合材料和第二粘合材料的液体粘合剂组合物至铺展的单向纤维的干纤维网以形成经粘合剂处理的纤维网；
干燥经粘合剂处理的纤维网；
结合非织造遮蔽物至所述纤维网的至少一侧以形成层合材料；
切割所述层合材料以形成适合自动带铺放的带，
其中第一粘合材料不同于第二粘合材料并选自：
i. 粘合剂，其在最高至50℃的温度下为固体，软化点为75℃至125℃范围的温度，其通过DSC测量，并包含环氧树脂和热塑性聚合物的共混物，但不含在高于75℃下有活性的任何催化剂或交联剂；和
ii. 液体组合物，其包含至少一种多官能环氧树脂；至少一种热塑性聚合物；和至少一种选自阴离子表面活性剂和非离子表面活性剂的表面活性剂；和
其中第二粘合材料为包含至少一种以下物质的水性分散体：
iii. 多羟基醚和聚氨酯的共聚物，氨基塑料交联剂；和任选地，催化剂；
iv. 聚氨酯，和任选地，交联剂；
v. 环氧树脂，和任选地，交联剂；和
vi. 苯氧树脂；和任选地，交联剂。
23.制造用于自动带铺放的干纤维带的方法，所述方法包括：
施加微粒形式或液体形式的第一粘合材料至非织造遮蔽物；
结合所述非织造遮蔽物至铺展的单向纤维的纤维网的至少一侧以形成层合材料；
施加液体组合物形式的第二粘合材料至所述层合材料，从而形成经粘合剂处理的层合材料；
干燥经粘合剂处理的层合材料；和
切割经干燥的层合材料以形成适合自动带铺放的带，
其中第一粘合材料不同于第二粘合材料并选自：
i. 粘合剂，其在最高至50℃的温度下为固体，软化点为75℃至125℃范围的温度，其通过DSC测量，并包含环氧树脂和热塑性聚合物的共混物，但不含在高于75℃下有活性的任何催化剂或交联剂；或
ii. 液体组合物，其包含至少一种多官能环氧树脂；至少一种热塑性聚合物；和至少一种选自阴离子表面活性剂和非离子表面活性剂的表面活性剂；和
其中第二粘合材料为包含至少一种以下物质的水性分散体：
iii. 多羟基醚和聚氨酯的共聚物，氨基塑料交联剂；和任选地，催化剂；
iv. 聚氨酯，和任选地，交联剂；
v. 环氧树脂，和任选地，交联剂；和
vi. 苯氧树脂；和任选地，交联剂。
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- 2015-06-25 BR BR112016030776-3A patent/BR112016030776B1/pt not_active IP Right Cessation
- 2015-06-25 WO PCT/US2015/037674 patent/WO2016003763A2/en active Application Filing
- 2015-06-25 AU AU2015284500A patent/AU2015284500B2/en not_active Ceased
- 2015-06-25 MY MYPI2016002256A patent/MY188591A/en unknown
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- 2015-06-25 RU RU2017102666A patent/RU2017102666A/ru not_active Application Discontinuation
- 2015-06-25 JP JP2017520746A patent/JP6654632B2/ja active Active
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| CN111699210A (zh) * | 2018-03-06 | 2020-09-22 | 东丽株式会社 | 纤维铺放用干式带材料及其制造方法、以及使用其的增强纤维层叠体及纤维增强树脂成型体 |
| CN111699210B (zh) * | 2018-03-06 | 2023-10-31 | 东丽株式会社 | 纤维铺放用干式带材料及其制造方法、以及使用其的增强纤维层叠体及纤维增强树脂成型体 |
| CN113661056A (zh) * | 2019-03-29 | 2021-11-16 | 塞特工业公司 | 具有雷击保护能力的可渗透材料及其在树脂灌注加工中的用途 |
| CN114454593A (zh) * | 2021-12-20 | 2022-05-10 | 东华大学 | 一种含无机非织造网纱的复合碳纤维带的制备方法 |
| CN115847935A (zh) * | 2023-03-02 | 2023-03-28 | 新创碳谷集团有限公司 | 一种干纤维带制备方法 |
Also Published As
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| KR20170026526A (ko) | 2017-03-08 |
| ES2712869T3 (es) | 2019-05-16 |
| EP3160720A2 (en) | 2017-05-03 |
| AU2015284500A1 (en) | 2017-01-05 |
| JP2017521291A (ja) | 2017-08-03 |
| AU2015284500B2 (en) | 2019-03-07 |
| BR112016030776B1 (pt) | 2021-06-29 |
| US20150375461A1 (en) | 2015-12-31 |
| MX363040B (es) | 2019-03-06 |
| RU2017102666A (ru) | 2018-08-06 |
| CA2953778C (en) | 2022-07-12 |
| CA2953778A1 (en) | 2016-01-07 |
| MY188591A (en) | 2021-12-22 |
| MX2016016711A (es) | 2017-11-02 |
| KR102267769B1 (ko) | 2021-06-21 |
| RU2017102666A3 (zh) | 2019-01-30 |
| WO2016003763A2 (en) | 2016-01-07 |
| JP6654632B2 (ja) | 2020-02-26 |
| WO2016003763A3 (en) | 2016-03-31 |
| BR112016030776A2 (pt) | 2017-08-22 |
| BR112016030776A8 (pt) | 2021-05-04 |
| US10583615B2 (en) | 2020-03-10 |
| EP3160720B1 (en) | 2018-11-21 |
| TW201614123A (en) | 2016-04-16 |
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