EP3553213B1 - Élément torsadé composite allongé et procédé de fabrication d'un tel élément - Google Patents

Élément torsadé composite allongé et procédé de fabrication d'un tel élément Download PDF

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Publication number
EP3553213B1
EP3553213B1 EP19166625.4A EP19166625A EP3553213B1 EP 3553213 B1 EP3553213 B1 EP 3553213B1 EP 19166625 A EP19166625 A EP 19166625A EP 3553213 B1 EP3553213 B1 EP 3553213B1
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EP
European Patent Office
Prior art keywords
elongate element
elongate
fabric
elongate elements
polymeric material
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EP19166625.4A
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German (de)
English (en)
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EP3553213A3 (fr
EP3553213A2 (fr
Inventor
John Patrick HYND
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Don and Low Ltd
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Don and Low Ltd
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Publication of EP3553213A3 publication Critical patent/EP3553213A3/fr
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    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/22—Yarns or threads characterised by constructional features, e.g. blending, filament/fibre
    • D02G3/40—Yarns in which fibres are united by adhesives; Impregnated yarns or threads
    • D02G3/402—Yarns in which fibres are united by adhesives; Impregnated yarns or threads the adhesive being one component of the yarn, i.e. thermoplastic yarn
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/04—Blended or other yarns or threads containing components made from different materials
    • D02G3/045—Blended or other yarns or threads containing components made from different materials all components being made from artificial or synthetic material
    • D—TEXTILES; PAPER
    • D02—YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02G—CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00—Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02—Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/06—Threads formed from strip material other than paper
    • D—TEXTILES; PAPER
    • D10—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B—INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES
    • D10B2505/00—Industrial
    • D10B2505/02—Reinforcing materials; Prepregs

Definitions

  • This invention relates to a composite thermoplastic polymer twisted tape or yarn, to a fabric or material formed from said tape or yarn, to an article, item or product made from said fabric or material, such as a thermoformed article, and to a method of making or forming the same.
  • the composite material or fabric may be suitable for a variety of applications.
  • composite materials or fabrics of the present invention may be comprised in articles used for high impact, anti-ballistic and/or defensive purposes.
  • Composite materials or fabrics of the present invention may be comprised in articles to afford high-impact resistance properties.
  • Embodiments of the present invention relate to composite twisted elongate elements, such as tapes or yarns, which may be used to produce a fabric or material incorporating similar or dissimilar materials in the warp and weft, such fabric being suitable for consolidating into single layer or multilayer shells or structures, e.g. under the action of heat and pressure without the need for additional resin or adhesive.
  • srPP Self-reinforcing polypropylene
  • WO 91/11324 discloses a thermoplastic composite material or tape comprising a molecularly-oriented thermoplastic polymer base having at least one thermoplastic surface polymeric layer compatibly bonded to said polymer base by molecular interspersion between the contiguous surfaces of the adjoining base and surface layers, and said surface polymeric layer having a softening temperature lower than that of the polymer base.
  • GB 2 492 644 discloses a fabric or material comprising: at least first elongate elements and second elongate elements that are mutually interspersed; wherein the first elongate elements comprise a polymer base and at least one polymeric surface layer, wherein the at least one polymeric surface layer has a softening temperature lower than that of the polymer base; and wherein at least a surface of the second elongate elements comprises an ultra high molecular weight polyalkylene (UHMWPA), wherein the ultra high molecular weight polyalkylene is a material dissimilar to the polymeric surface layer, and the first elongate elements are fusible together with the second elongate elements at least at intersections.
  • UHMWPA ultra high molecular weight polyalkylene
  • molecular interspersion is meant the intimate molecular compatibility of molecules of the surface layer and the adjacent polymer and vice versa, so that there is intermingling or fusion at their contiguous boundaries. It is believed that such molecular interspersion effectively forms an amorphous sheath which protects the polymer base against fracture during drawing, thus providing mutual mechanical reinforcement.
  • US 2008/0182471 discloses a yarn comprising a multifilamentary core, comprising many filaments of material of lower melting point, wrapped by at least one and preferably two multifilamentary strands, each also comprising filaments of material of higher melting point.
  • US 4 275 117 discloses a string made of a core comprising a plurality of low melt twisted filamentous strands which is then provided with a high melt sheath on its outer side.
  • US 5 366 797 discloses a multifilament yarn.
  • Mutual mechanical reinforcement involves the surface material being capable of high elongation when drawn in the solid state (or even being drawn at a temperature above its softening point, i.e. in the molten state). With a polymer layer of high modulus, and crystalline or oriented material sandwiched between amorphous high elongation surface layers, propagation of transverse fractures is inhibited allowing the total composite to be highly drawn.
  • Coextruded yarns of thermoplastic polymers of at least A-B construction, where A has a melting temperature at least 10°C below that of B can be formed into fabrics eg. woven fabrics, which can, in turn, be formed into three dimensional shaped articles under the influence of heat and pressure without the need for additional adhesives or films.
  • these yarns can be limited in their ratio of A to (A+B) to between 1 to 30% or less, more typically 1 to 15% or less. This can limit the strength of bonding of the tape or yarn both internally to itself and also externally to other materials.
  • a fabric can be made from said tapes or yarns, e.g. by weaving, which is capable of being formed into 2 or 3 dimensional items under the action of heat and pressure both by itself and in conjunction with dissimilar materials. The bond strength of such fabric can be limited.
  • the fabric or material may, therefore, be self-adhering or self-supporting.
  • a composite twisted elongate element comprising a plurality of elongate elements twisted together and which comprise at least one first elongate element and at least one second elongate element, wherein each of said plurality of elongate elements is substantially planar prior to twisting, the at least one first elongate element consists of a single homogeneous layer consisting of a first thermoplastic polymeric material A and the at least one second elongate element consists of a single homogeneous layer consisting of a second molecularly-oriented thermoplastic polymeric material B.
  • the melting point or softening point of the first polymeric material is at least 10°C less than the melting point or softening point of the second polymeric material, and the first and second polymeric materials are capable of being autogeneously bonded.
  • 'composite elongate element' is meant to comprise or include a plurality of elongate elements, yarns, tapes, strands, plies, or fibres that are twisted together.
  • twisting together of the plurality of elongate elements may provide advantage over the prior art, e.g. weaving together of single yarns.
  • An advantage may be beneficial increased distribution of the first polymeric material throughout a matrix of a material or fabric, e.g. a woven material.
  • the first polymeric material may comprise a first polyolefin.
  • the second polymeric material may comprise a second polyolefin.
  • the first polymeric material acts as a matrix binder or adhesive agent within the material or fabric.
  • the second polymeric material acts as a strengthening or integrity providing agent within the material or fabric.
  • Each of the plurality of elongate elements and/or the composite elongate elements may have tensile strength, but may be too flexible to provide compressive strength.
  • The/each of the plurality of elongate elements and/or composite elongate elements may be coilable or reelable.
  • the composite elongate element(s) may be capable of being woven.
  • the composite twisted elongate elements may be twisted or 'laid' together.
  • the second polymeric material may comprise polypropylene, e.g. polypropylene homopolymer.
  • the first polymeric material may comprise polyethylene, e.g. polyethylene homopolymer.
  • the composite twisted elongate element may comprise one or more first elongate elements twisted together with one or more second elongate elements.
  • the composite twisted elongate element may comprise a first elongate element twisted together with a second elongate element.
  • the composite twisted elongate element may comprise one first elongate element twisted together with two second elongate elements.
  • the composite twisted elongate element may comprise one first elongate element twisted together with three second elongate elements.
  • the composite twisted elongate element may comprise one or more first elongate elements twisted together with one or more second elongate elements so as to form a composite twisted elongate element, and two or more of said composite twisted elongate elements are twisted together.
  • a first twist between the first and second elongate elements there is provided a second twist between the two or more composite twisted elongate elements.
  • the first and second elongate elements may have a similar or substantially the same tex (mass in grams per 1,000 metres), e.g. 70 to 200 grams/1,000 metres, or 100 to 130 grams/1,000 metres).
  • the plurality of elongate elements may comprise two elongate elements. In another embodiment of the present invention the plurality of elongate elements may comprise three elongate elements. Alternatively, the plurality of elongate elements may comprise more than three elongate elements.
  • the plurality of elongate elements may be twisted together in a left-handed or S-twist or in a right-handed or Z-twist (according to ISO 2).
  • each of the plurality of (e.g. first and/or second) elongate elements may be a tape, orior to twisting.
  • Each of the plurality of elongate elements may be an extruded tape, for example, made by an extrusion process.
  • the at least one second elongate element may comprise a self-reinforcing polymeric material such as self-reinforcing polypropylene (srPP).
  • srPP self-reinforcing polypropylene
  • The/each at least one second elongate element may be selected from polypropylene, polyesters, polyethyleneterephthalate, polyamides, Nylon (e.g. Nylon 6 or 6.6), or a polyethylene, e.g. having a density in the range 0.940 to 0.970, or linear low density polyethylene.
  • the second polymeric material may comprise a molecularly-oriented polyolefin polymer, such as a polypropylene polymer.
  • the first polymeric material may comprise ethylene-propylene co-polymer, polybutylene, polybutene-1 or a co-polymer comprising two or more of butylene, ethylene and propylene, co-polyesters and co-polyamides.
  • the second polymeric material may comprise polypropylene and/or the first polymeric material may comprise an ethylene-propylene co-polymer, a polybutylene such as polybutene-1 or a co-polymer comprising two or more of butylene, ethylene and propylene.
  • the second polymeric material may comprise polyester and/or the first polymeric material may comprise a co-polyester, or the second polymeric material may be a polyamide and the first polymeric material may comprise a co-polyamide.
  • a material or fabric comprising at least one composite twisted elongate element according to the first aspect of the present invention.
  • the material or fabric may comprise a plurality of composite twisted elongate elements according to the first aspect of the present invention.
  • the material or fabric may advantageously comprise a single layer of material or fabric.
  • the material or fabric e.g. advantageously single layer of material or fabric, may be consolidated or consolidatable, e.g. by application of heat and/or pressure.
  • the material or fabric of the present invention has been found to possibly provide advantages over the prior art, e.g. it has been found that since a single layer of the material or fabric may be heavier than a single layer of single yarn weave of the prior art, whereas in the prior art single layers have been laminated together to provide a suitable material for forming of a product, a single layer of fabric of the present invention suffices. This may avoid the need for lamination, so simplifying the manufacturing process and/or obviating and/or mitigating the problem of delamination.
  • the material or fabric may also comprise a plurality of further elongate elements, e.g. twisted elongate elements, which may be polymeric.
  • the plurality of further elongate elements may beneficially be the same as the plurality of composite twisted elongate elements.
  • the plurality of composite twisted elongate elements and plurality of further elongate elements may be mutually interspersed.
  • At least some of the further elongate elements may comprise a material or materials similar or dissimilar to the first polymeric material.
  • Adjacent, e.g. side-by-side, overlaid, cross-laid or intersecting, elongate elements may be fusible together at least at intersections.
  • Fusing may comprise heating the fabric above the melting temperature of the first polymeric material A, e.g. at a temperature between MP A and MP B .
  • Fusing may comprise cooling the fabric to allow the surface layer to solidify.
  • Fusing the elements may comprise subjecting the fabric to pressure. Fusing may be achieved by single closure press with flat or contoured plates, continuous belt press, induction heated press or via vacuum bagging and autoclaving.
  • the material or fabric may comprise a woven material or fabric.
  • the material or fabric may comprise at least one mat of mutually intersecting composite twisted elongate elements fusible together at least at their intersections.
  • thermoplastic material or fabric may comprise a consolidated mat or sheet, wherein the plurality of composite twisted elongate elements may have been consolidated together, e.g. by application of heat and/or pressure.
  • the fabric or material may be formed without the use of, for example, a resin matrix material, a film or an adhesive.
  • the further elongate elements may be selected from tapes, threads, fibres, filaments, strands, or the like.
  • the further elongate elements may comprise a single layer and/or homogenous layer.
  • the further elongate elements may comprise a material similar or dissimilar to the first polymeric material.
  • the elongate elements and the further elongate elements may be formed as tapes.
  • the composite twisted elongate elements and/or further elongate elements may be woven, knitted, stitched, or may be laid out to form a random fibrous web or may be randomly interspersed to form the material.
  • the composite twisted elongate elements and/or further elongate elements may be woven together to form a fabric.
  • the composite twisted elongate elements and further elongate elements may be woven together to form the fabric or material.
  • the warp may be formed of composite twisted or further elongate elements and the weft may be formed of the other.
  • the warp may be formed of composite twisted elongate elements and the weft may be formed of further elongate elements.
  • the warp may be formed of further elongate elements and the weft may be formed of composite twisted elongate elements.
  • the composite twisted and further elongate elements may be woven together to form the fabric or material, and the warp and/or the weft may comprise a mixture of composite twisted and further elongate elements.
  • the mixture of composite twisted and further elongate elements may be a random arrangement of composite twisted and further elongate elements.
  • the mixture of composite twisted and further elongate elements may be a regular alternation of composite twisted and elongate elements.
  • warp and weft may comprise, e.g. solely comprise, the composite twisted elongate elements.
  • the further elongate elements may comprise one or more of: polyesters, polyamides, aramids, thermoplastic polymers, molecularly-oriented thermoplastic polymers, ultra high molecular weight polyalkylenes (UHMWPA), such as ultra high molecular weight polyethylene (UHMWPE) or ultra high molecular weight polypropylene (UHMWPP), multifilament nucleated polypropylenes, and/or carbon fibres.
  • UHMWPA ultra high molecular weight polyalkylenes
  • UHMWPE ultra high molecular weight polyethylene
  • UHMWPP ultra high molecular weight polypropylene
  • multifilament nucleated polypropylenes and/or carbon fibres.
  • the further elongate elements may be formed of hybrid yarns.
  • the hybrid yarns may be formed of at least two different materials or fibres comprising polyesters, polyamides, aramids, thermoplastic polymers, molecularly-oriented thermoplastic polymers, ultra high molecular weight polyalkylenes (UHMWPA), such as ultra high molecular weight polyethylene (UHMWPE) or ultra high molecular weight polypropylene (UHMWPP), multifilament nucleated polypropylenes, and/or carbon fibres.
  • UHMWPA ultra high molecular weight polyalkylenes
  • UHMWPE ultra high molecular weight polyethylene
  • UHMWPP ultra high molecular weight polypropylene
  • multifilament nucleated polypropylenes and/or carbon fibres.
  • the further elongate elements may be formed of hybrid yarns selected from hybrid yarns comprising aramids and UHMWPE or hybrid yarns comprising polypropylene.
  • the further elongate elements may comprise or consist of ultra high molecular weight polyalkylenes selected from UHMWPE or UHMWPP.
  • a laminated material such as a rigid and/or self-supporting laminated material, comprising a plurality of layers, wherein at least one of said layers comprises a material or fabric according to the second aspect of the present invention.
  • the laminated material comprises two layers, e.g. only two layers, or three layers, e.g. only three layers.
  • each layer comprises a material or fabric according to the second aspect of the present invention.
  • an article such as a formed and/or three-dimensional and/or rigid and/or self-supporting article, formed from a (single layer of) material or fabric of the second aspect of the present invention, or alternatively formed from a laminated material of the third aspect of the present invention.
  • the article may be formed by a moulding technique, e.g. press-moulding.
  • the article may be capable of withstanding relatively high impact, i.e. the article may have high impact resistance properties.
  • the article may comprise a luggage shell, e.g. a shell for a suitcase, or at least part of a container.
  • the article may comprise or be selected from: an armour product, e.g. body armour, an automotive (vehicle) component, a sportswear product.
  • the article may be adapted for antiballistic purposes and/or comprises bulletproof vests, body armour, panels suitable for the protection of vehicles, such as military and/or commercial vehicles, bin liners, blast basket or blast blankets to contain fragmentation debris from the detonation of explosive devices.
  • the article may find use as carpet backing which may be used in automotive or aerospace application, or which may comprise panels suitable for use on automotive vehicles.
  • the article may comprise a toe-cap(s) for protective footwear, connecting straps of handles of intermediate bulk containers or the containers themselves, tarpaulins, packaging, luggage, protective cases, pipes.
  • a method of forming a composite twisted elongate element comprising:
  • a method of forming a fabric or material comprising:
  • Said fabric or material may comprise a sheet or mat.
  • Said step of providing may also comprise providing a plurality of further elongate elements, which may be polymeric.
  • Said step of forming may comprise weaving.
  • the plurality of composite twisted elongate elements may comprise warp yarns.
  • the plurality of composite twisted elongate elements may comprise weft yarns.
  • the method may further comprise the (subsequent) step of consolidating the fabric or material, e.g. single layer fabric or material, by application of heat and/or pressure.
  • a seventh aspect of the present invention there is provided a method of forming an article, such as a three-dimensional and/or rigid and/or self-supporting article, comprising the steps of:
  • first to fourth embodiments of a composite twisted elongate element 5; 5a to 5d comprising a plurality of elongate elements 10 twisted together and which comprise at least one first elongate element 20 and at least one second elongate element 25, wherein each first elongate element 20 consists of a first polymeric material A and each second elongate element 25 consists of a second polymeric material B.
  • composite twisted elongate elements according to the present invention provide benefit/advantage over prior art elongate elements comprising coextruded elongate elements, e.g. of the construction A-B or A-B-A, where B comprises a polymeric base or substrate, and A comprises at least one polymeric surface layer or opposing polymeric surface layers.
  • twisting together of the plurality of elongate elements provides advantage over the prior art, e.g. weaving together of single yarns.
  • An advantage is believed to be beneficial increased distribution of the first polymeric material throughout a matrix of a material or fabric, e.g. a woven material.
  • the first polymeric material A comprises a first polyolefin.
  • the second polymeric material B comprises a second polyolefin.
  • the first polymeric material A acts as a matrix binder or adhesive agent within the material or fabric.
  • the second polymeric material B acts as a strengthening or integrity providing agent within the material or fabric.
  • Each of the plurality of elongate elements 10 and/or the composite elongate elements 5; 5a to 5d have tensile strength, but are too flexible to provide compressive strength.
  • The/each of the plurality of elongate elements 10 and/or composite elongate elements 5; 5a to 5d are coilable or reelable.
  • the composite elongate element(s) 5; 5a to 5d are capable of being woven.
  • the elongate elements 10; 5; 5a to 5d are twisted or 'laid' together.
  • the first polymeric/polyolefinic material and the second polymeric/polyolefinic material are dissimilar, i.e. dissimilar polymers/polyolefins.
  • the melting point or softening point MP A of the first polymeric material is lower than the melting point or softening point MP B of the second polymeric material.
  • the first and second polymeric materials are thermally compatible, and capable of being autogenously bonded.
  • the melting point MP A of the first polymeric material is at least 10°C less than the melting point MP B of the second polymeric material.
  • the first elongate element(s) 20 solely consist of the first polymeric material A, e.g. a first homopolymer.
  • the second elongate element(s) 25 solely consist of the second polymeric material B, e.g. a second homopolymer.
  • the first elongate element(s) 20 comprise a single homogeneous layer.
  • the second elongate element(s) 25 comprise a single homogeneous layer.
  • the second polymeric material comprises polypropylene, e.g. polypropylene homopolymer.
  • the first polymeric material comprises polyethylene, e.g. polyethylene homopolymer.
  • the elongate element 5; 5a to 5d comprises one or more first elongate elements 20 twisted together with one or more second elongate elements 25.
  • the second elongate element is: extruded, made from polypropylene, highly drawn, has molecularly aligned polymer chains, and/or has a melting point (MP B ) of 165°C or higher.
  • the first elongate element is: extruded and/or made from polyethylene.
  • the first elongate element need not be highly drawn to achieve molecular alignment. This is because the first elongate element melts away, in use, to form a matrix material, and if there is not molecular alignment, material shrinkage can be avoided.
  • the first elongate element is sacrificially melted in the elongate element or fabric or article made therefrom.
  • the polyethylene has a melting point MP A of around 134°C.
  • the elongate element 5a comprises a first elongate element 20 twisted together with a second elongate element 25.
  • first elongate element 20 can be twisted together with a second elongate element 25, e.g. of the same or similar tex (mass in grams of 1,000 metres).
  • the twist level is typically between 20 and 60 turns per metre, preferably around 40 tpm.
  • the resultant twisted element can be used to construct a fabric, e.g. a woven fabric. Said woven fabric made from said elements can then be formed into a three dimensionally formed article by the action of heat and pressure in a mould, said article then being cooled in the mould prior to release.
  • forming can be of a single layer of fabric or of multiple layers of fabric.
  • the resultant article can then display superior lamination strength versus a similar fabric formed only from conventionally coextruded A-B or A-B-A tapes or yarns with a lower ratio of A to (A+B), e.g. 15% versus 50% for the present invention.
  • the elongate element 5b comprises one first elongate element 20 twisted together with two second elongate elements 25.
  • two tapes of type B are twisted with a single tape of type A of similar tex to yield a twisted tape equivalent to 33.33% cap layer (ratio of A to (A+B)).
  • the elongate element 5c comprises one first elongate element 20 twisted together with three second elongate elements 25.
  • three tapes of type B are twisted with a ratio single tape of type A of very similar tex to yield a twisted tape equivalent to 25% cap layer (ratio of A to (A+B)), which is around twice that which can be achieved with conventionally coextruded A-B or A-B-A tapes or yarns.
  • the elongate element 5d comprises one or more first elongate elements 20 twisted together with one or more second elongate elements 25 so as to form a composite twisted elongate element 5a, and two or more of said composite twisted elongate elements are twisted together.
  • first twist between the first and second elongate elements 20, 25.
  • second twist between the two or more composite twisted elongate elements 5a.
  • one tape of type A is twisted with one tape of type B. Then, two of said twisted A-B tapes are further twisted together with each other to yield a composite tape of two B and two A type tapes.
  • 'cap' layer A can thus be improved versus a typical side-by-side coextruded tape or yarn of A-B or A-B-A construction. Fabrics woven from said tapes, and articles processed from said fabrics may demonstrate superior internal bond strength or lamination strength due to the improved distribution of lower melt layer A.
  • the first and second elongate elements 20, 25 advantageously have a similar or substantially the same tex (mass in grams per 1,000 metres), e.g. 70 to 200 grams/1,000 metres, or 100 to 130 grams/1,000 metres).
  • tex masses in grams per 1,000 metres
  • 20 to 60 e.g. 40 to 60
  • twists/turns per metre (tpm) twists/turns per metre (tpm)
  • tpm twists/turns per metre
  • the plurality of elongate elements comprise two elongate elements, and in the second embodiment of the present invention the plurality of elongate elements comprise three elongate elements, in an alternative embodiment the plurality of elongate elements 10 can comprise more than three elongate elements 20, 25.
  • the plurality of elongate elements 20, 25; 5a to 5d can be twisted together in a left-handed or S-twist or in a right-handed or Z-twist (according to ISO 2).
  • each of the plurality of elongate elements is planar, e.g. comprises a tape, prior to twisting.
  • The/each elongate element 20, 25 is an extruded yarn or tape, for example, made by an extrusion process.
  • the at least one second elongate element 25 comprises a self-reinforcing polymeric material such as self-reinforcing polypropylene (srPP).
  • srPP self-reinforcing polypropylene
  • Each elongate element 20, 25 comprises a thermoplastic.
  • Each second elongate element 25 comprises a molecularly-oriented thermoplastic polymeric material.
  • The/each at least one second elongate element 25 can be selected from polypropylene, polyesters, polyethyleneterephthalate, polyamides, Nylon (e.g. Nylon 6 or 6.6), or a polyethylene, e.g. having a density in the range 0.940 to 0.970, or linear low density polyethylene.
  • the second polymeric material B comprises a molecularly-oriented polyolefin polymer, such as a polypropylene polymer.
  • the first polymeric material A comprises a thermoplastic polymer.
  • the first polymeric material A can comprise ethylene-propylene co-polymer, polybutylene, polybutene-1 or a co-polymer comprising two or more of butylene, ethylene and propylene, co-polyesters and co-polyamides.
  • the second polymeric material B can be polypropylene and/or the first polymeric material A can comprise an ethylene-propylene co-polymer, a polybutylene such as polybutene-1 or a co-polymer comprising two or more of butylene, ethylene and propylene.
  • the second polymeric material B can be polyester and/or the first polymeric material A can comprise a co-polyester, or the second polymeric material B can be a polyamide and the first polymeric material can comprise a co-polyamide.
  • the first polymeric material A is autogenously bondable with the second polymeric material B.
  • the second polymeric material B has a softening point of 10°C or more higher than the softening point of the first polymeric material A.
  • a material or fabric 100 such as a thermoplastic composite material according to an embodiment of the present invention, comprising at least one elongate element 5a to 5d of Figures 1 to 4 .
  • the material or fabric 100 comprises a plurality of composite twisted elongate elements 5; 5a to 5d.
  • the material or fabric 100 advantageously comprise a single layer of material or fabric 100.
  • the material or fabric 100 e.g. advantageously single layer of material or fabric, can be consolidated or is consolidatable, e.g. by application of heat and/or pressure.
  • the material or fabric 100 has been found to possibly provide advantages over the prior art, e.g. it has been found that since a single layer of the material or fabric 100 can be heavier than a single layer of single yarn weave of the prior art, whereas in the prior art single layers have been laminated together to provide a suitable material for forming of a product, a single layer of material or fabric 100 of the present invention suffices. This can avoid the need for lamination, so simplifying the manufacturing process and/or obviating and/or mitigating the problem of delamination.
  • the material or fabric 100 can also comprise a plurality of further elongate elements 105, e.g. twisted elongate elements, which are polymeric.
  • the plurality of further elongate elements 105 can beneficially be the same as the plurality of composite twisted elongate elements 5a to 5d.
  • the plurality of composite twisted elongate elements 5a to 5d and plurality of further elongate elements 105 can be mutually interspersed. At least some of the further elongate elements 105 can comprise a material or materials similar or dissimilar to the first polymeric material.
  • Adjacent, e.g. side-by-side, overlaid, cross-laid or intersecting, elongate elements 5a to 5d can be fused together at least at intersections.
  • Fusing can comprise heating the fabric above the melting temperature of the first polymeric material A, e.g. to a temperature between MP A and MP B .
  • Fusing can comprise cooling the fabric to allow the surface layer to solidify.
  • Fusing the elements can comprise subjecting the fabric to pressure. Fusing can be achieved by single closure press with flat or contoured plates, continuous belt press, induction heated press or via vacuum bagging and autoclaving.
  • Figure 6 shows the fabric 100 after consolidation via a combination of heat and/or pressure.
  • the fabric 100 comprises a woven fabric.
  • the fabric 100 comprises at least one mat of mutually intersecting elongate elements 5a to 5d, 105 fusible together at least at their intersections.
  • the further elongate elements 105 can comprise a single layer or homogenous layer.
  • the further elongate elements 105 can comprise a material or materials similar or dissimilar to the first polymeric material A.
  • the composite twisted elongate elements 5a to 5d and the further elongate elements 105 are formed as tapes.
  • the elongate elements 20, 25; 5a to 5d comprise one or two surface layers or two opposing surface layers.
  • the material or fabric 100 typically comprises a woven material or fabric.
  • the material or fabric 100 can comprise at least one mat of mutually intersecting elongate elements fusible together at least at their intersections.
  • the thermoplastic material or fabric 100 comprises a consolidated mat or sheet, wherein the plurality of composite twisted elongate elements 5a to 5b have been consolidated together, e.g. by application of heat and/or pressure.
  • the fabric or material can be formed without the use of, for example, a resin matrix material, a film or an adhesive.
  • the elongate elements 20, 25; 5a to 5d and/or further elongate elements 105 can be selected from tapes, threads, fibres, filaments, strands, or the like.
  • the further elongate elements can comprise a single layer and/or homogenous layer.
  • the further elongate elements can comprise a material similar or dissimilar and/or thermally compatible and/or autogenously bondable with the first polymeric material.
  • the elongate elements 20, 25; 5a to 5d and the further elongate members 105 can be formed as tapes.
  • the composite twisted elongate elements 5a to 5d and/or further elongate elements can be woven, knitted, stitched, or can be laid out to form a random fibrous web or may be randomly interspersed to form the material.
  • the composite twisted elongate elements 5a to 5d and/or further elongate elements 105 can be woven together to form a fabric.
  • the composite twisted elongate elements 5a to 5d and further elongate elements 105 can be woven together to form the fabric or material 100.
  • the warp can be formed of composite or further elongate elements 5a to 5d and the weft may be formed of the other.
  • the warp can be formed of composite elongate elements 5a to 5d and the weft may be formed of further elongate elements 105.
  • the warp can be formed of further elongate elements 105 and the weft may be formed of composite elongate elements 5a to 5d.
  • the further elongate elements 105 can be the same as (i.e. can be identical to) the composite twisted elongate elements 5a to 5d.
  • the composite and further elongate elements can be woven together to form the fabric or material, and the warp and/or the weft may comprise a mixture of composite and further elongate elements.
  • the mixture of composite and further elongate elements can be a random arrangement of composite and further elongate elements.
  • the mixture of composite and further elongate elements can be a regular alternation of composite and elongate elements.
  • warp and weft can comprise, e.g. solely comprise, the composite elongate elements 5a to 5d.
  • the further elongate elements 105 can comprise one or more of: polyesters, polyamides, aramids, thermoplastic polymers, molecularly-oriented thermoplastic polymers, ultra high molecular weight polyalkylenes (UHMWPA), such as ultra high molecular weight polyethylene (UHMWPE) or ultra high molecular weight polypropylene (UHMWPP), multifilament nucleated polypropylenes, and/or carbon fibres.
  • UHMWPA ultra high molecular weight polyalkylenes
  • UHMWPE ultra high molecular weight polyethylene
  • UHMWPP ultra high molecular weight polypropylene
  • multifilament nucleated polypropylenes and/or carbon fibres.
  • the further elongate elements can be formed of hybrid yarns.
  • the hybrid yarns can be formed of at least two different materials or fibres comprising polyesters, polyamides, aramids, thermoplastic polymers, molecularly-oriented thermoplastic polymers, ultra high molecular weight polyalkylenes (UHMWPA), such as ultra high molecular weight polyethylene (UHMWPE) or ultra high molecular weight polypropylene (UHMWPP), multifilament nucleated polypropylenes, and/or carbon fibres.
  • UHMWPA ultra high molecular weight polyalkylenes
  • UHMWPE ultra high molecular weight polyethylene
  • UHMWPP ultra high molecular weight polypropylene
  • multifilament nucleated polypropylenes and/or carbon fibres.
  • the further elongate elements 105 can be formed of hybrid yarns selected from hybrid yarns comprising aramids and UHMWPE or hybrid yarns comprising polypropylene.
  • the further elongate elements 105 can comprise or consist of ultra high molecular weight polyalkylenes selected from UHMWPE or UHMWPP.
  • the laminated material 200 (which is rigid or nondrapable at normal room/ambient temperature) comprises a plurality of layers 205, wherein at least one of said layers 205 comprise the fabric 100.
  • the laminated material 200 comprises two layers 205, e.g. only two layers, or alternatively three layers, e.g. only three layers (see Figure 8 ).
  • each layer 205 comprises the fabric 100.
  • articles i.e. three-dimensional (rigid or self-supporting) articles formed from fabric 100, or alternatively formed from the laminated material 200.
  • the articles 400a to 400d are typically formed by a moulding technique, e.g. press-moulding.
  • the articles 400a to 400d are capable of withstanding relatively high impact, i.e. the articles 400a to 400d have relatively high impact resistance properties.
  • the article 400a comprises a luggage shell, e.g. a shell for a suitcase.
  • the article can comprise or be selected from: a container, an armour product, e.g. body armour, automotive (vehicle) component, sportswear product.
  • the article can be adapted for high impact and/or antiballistic purposes, and/or comprises bulletproof vests, body armour, panels suitable for the protection of military and commercial vehicles, bin liners, blast basket or blast blankets to contain fragmentation debris from the detonation of explosive devices.
  • the article may find use as carpet backing which may be used in automotive or aerospace application or which comprises panels suitable for use on automotive vehicles.
  • the article 400b comprises a toe-cap(s) for protective footwear.
  • the article can comprise connecting straps of handles of intermediate bulk containers or the containers themselves, tarpaulins, packaging, luggage, protective cases, pipes.
  • Figure 12 shows an article 400d comprising an automotive component (e.g. door trim) prior to finishing/trimming.
  • the present invention provides a method of forming a composite twisted elongate element 5, the method comprising:
  • the present invention provides a method of forming a fabric or material 100, the method comprising:
  • Said fabric 100 typically comprises a sheet or mat.
  • Said step of providing can also comprise providing a plurality of further elongate elements 105.
  • Said step of forming comprises weaving.
  • the plurality of composite twisted elongate elements 5a to 5d can comprise warp/weft yarns.
  • the plurality of composite twisted elongate elements can comprise weft/warp yarns.
  • the method further comprises the (subsequent) step of consolidating the fabric 100 by application of heat and/or pressure.
  • the present invention provides a method of forming an article 400, such as a three-dimensional article, comprising the steps of:
  • thermoformed articles are, therefore, less likely to be subject to failure by delamination.
  • the material can be failure averted and utility of the thermoformed parts enhanced.
  • the present invention seeks to provide a solution to one or more issues in the prior art by permitting the ratio of cap layer to be increased beyond that which can presently be realised by coextrusion.
  • the ratio of cap layer may, for example, be effectively tuned to any particular value between 1 and 50% or, indeed, higher.
  • a means is provided for tuning the cap layer ratio anywhere between 1 and 50% or even higher. Any ratio can be achieved by controlling the number of each type of tape or yarn incorporated into the twisting operation and by controlling the relative weight or tex of the at least one B tape with the at least one A tape or yarn.
  • the solution provides benefits by enhancing the bonding capacity of the twisted tapes or yarns to themselves, or for fabric constructed from said tapes or yarns to bind to itself or to other materials without the need for additional adhesives or films.
  • Articles made from said tapes or yarns or fabrics, whether bonded to themselves or also to other materials, can be made with a tuneable spectrum of properties, e.g. stiffness, delamination strength, impact strength, etc. All of this can be achieved without the need for additional adhesive or film.
  • the breadth of product performance may thus be widened, which may provide a wider range of applications to be served than is possible with current coextruded tape or yarn technology.

Landscapes

  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Woven Fabrics (AREA)
  • Ropes Or Cables (AREA)

Claims (16)

  1. Elément allongé torsadé composite (5a-5d), comprenant une pluralité d'éléments allongés (10) torsadés ensemble et qui comprennent au moins un premier élément allongé (20) et au moins un second élément allongé (25), dans lequel chaque élément de ladite pluralité d'éléments allongés est sensiblement plan avant d'être torsadé, l'au moins un premier élément allongé (20) est constitué d'une unique couche homogène constituée d'un premier matériau polymère thermoplastique (A), et l'au moins un second élément allongé (25) est constitué d'une unique couche homogène constituée d'un second matériau polymère thermoplastique à orientation moléculaire (B), et dans lequel le point de fusion ou le point de ramollissement (MPA) du premier matériau polymère est inférieur d'au moins 10 °C au point de fusion ou au point de ramollissement (MPB) du second matériau polymère, et les premier et second matériaux polymères sont aptes à être liés de manière autogène.
  2. Elément allongé torsadé composite selon la revendication 1, dans lequel :
    le premier matériau polymère comprend une première polyoléfine et le second matériau polymère comprend une seconde polyoléfine.
  3. Elément allongé torsadé composite selon l'une quelconque des revendications précédentes, dans lequel :
    le second matériau polymère comprend du polypropylène ; et/ou
    le premier matériau polymère comprend du polyéthylène.
  4. Elément allongé torsadé composite selon l'une quelconque des revendications 1 à 3, dans lequel :
    l'élément allongé (5a) comprend un premier élément allongé (20) torsadé conjointement avec un second élément allongé (25), ou
    l'élément allongé (5b) comprend un premier élément allongé torsadé conjointement avec deux seconds éléments allongés, ou
    l'élément allongé (5c) comprend un premier élément allongé torsadé conjointement avec trois seconds éléments allongés, ou
    l'élément allongé (5d) comprend un ou plusieurs premiers éléments allongés (20) torsadés conjointement avec un ou plusieurs seconds éléments allongés (25) de manière à former un élément allongé torsadé composite, et deux desdits éléments allongés torsadés composites ou plus sont torsadés ensemble de telle sorte qu'il est fourni une première torsade entre les premier et second éléments allongés et une seconde torsade entre les deux éléments allongés torsadés composites ou plus.
  5. Elément allongé torsadé composite selon l'une quelconque des revendications précédentes, dans lequel les premier et second éléments allongés ont un tex similaire ou sensiblement identique, sélectionné facultativement parmi : 70 à 200 grammes/1 000 mètres, ou 100 à 130 grammes/1 000 mètres ; et/ou il est fourni 20 à 100, 20 à 60, ou 40 à 60 torsades/tours par mètre (tpm), facultativement environ 40 tpm, sur une longueur de l'élément allongé torsadé composite et/ou de chaque élément de la pluralité d'éléments allongés.
  6. Elément allongé torsadé composite selon l'une quelconque des revendications précédentes, dans lequel chacun de ladite pluralité d'éléments allongés est un ruban, avant d'être torsadé.
  7. Elément allongé torsadé composite selon l'une quelconque des revendications précédentes, dans lequel :
    chacun de la pluralité d'éléments allongés est un ruban extrudé ; et/ou
    l'au moins un second élément allongé comprend un matériau polymère auto-renforcé tel qu'un polypropylène auto-renforcé (srPP).
  8. Elément allongé torsadé composite selon l'une quelconque des revendications précédentes, dans lequel :
    le/chaque au moins un second élément allongé est sélectionné parmi le polypropylène, les polyesters, le polyéthylène téréphtalate, les polyamides, le nylon, le polyéthylène ou le polyéthylène basse densité linéaire ; et/ou
    le premier matériau polymère comprend un copolymère d'éthylène-propylène, du polybutylène, du polybutylène-1 ou un copolymère comprenant deux composants ou plus parmi le butylène, l'éthylène et le propylène, les copolyesters et les copolyamides.
  9. Elément allongé torsadé composite selon l'une quelconque des revendications précédentes, dans lequel :
    le second matériau polymère est du polypropylène et/ou le premier matériau polymère comprend un copolymère d'éthylène-propylène, un polybutylène tel que le polybutène-1 ou un copolymère comprenant deux composants ou plus parmi le butylène, l'éthylène et le propylène ; ou
    le second matériau polymère est du polyester et/ou le premier matériau polymère comprend un copolyester, ou le second matériau polymère est un polyamide et le premier matériau polymère comprend un copolyamide.
  10. Matériau ou tissu (100), comprenant au moins un élément allongé torsadé composite (5a-5d) selon l'une quelconque des revendications 1 à 9.
  11. Matériau ou tissu selon la revendication 10, dans lequel :
    le matériau ou tissu comprend une unique couche de matériau ou tissu ; et/ou
    le matériau ou tissu est un matériau ou tissu tissé.
  12. Matériau laminé (200) comprenant une pluralité de couches, dans lequel au moins une desdites couches comprend un matériau ou tissu selon l'une ou l'autre de la revendications 10 ou 11.
  13. Article (400a-400d) formé à partir d'un matériau ou tissu selon l'une ou l'autre de la revendication 10 ou 11, ou formé à partir d'un matériau laminé selon la revendication 12.
  14. Procédé de formation d'un élément allongé torsadé composite (5a-5d), le procédé comprenant :
    la fourniture d'au moins un premier élément allongé plan (20) et d'au moins un second élément allongé plan (25) ;
    le torsadage desdits au moins un premier et au moins un second éléments allongés plans ensemble ; dans lequel
    l'au moins un premier élément allongé plan est constitué d'une unique couche homogène constituée d'un premier matériau polymère thermoplastique (A), et l'au moins un second élément allongé plan est constitué d'une unique couche homogène constituée d'un second matériau polymère thermoplastique à orientation moléculaire (B), et dans lequel le point de fusion ou point de ramollissement (MPA) du premier matériau polymère est inférieur d'au moins 10 °C au point de fusion ou point de ramollissement (MPB) du second matériau polymère, et les premier et second matériaux polymères sont aptes à être liés de manière autogène.
  15. Procédé de formation d'un tissu ou matériau (100), le procédé comprenant :
    la fourniture d'une pluralité d'éléments allongés torsadés composites selon l'une quelconque des revendications 1 à 9 ; et
    le façonnage dudit tissu ou matériau à partir de ladite pluralité d'éléments allongés.
  16. Procédé de formation d'un article (400a-400d), comprenant les étapes consistant à :
    fournir un tissu ou matériau selon l'une ou l'autre de la revendication 10 ou 11, ou un matériau laminé selon la revendication 12 ; et
    le façonnage de l'article à partir du tissu ou matériau.
EP19166625.4A 2018-04-12 2019-04-01 Élément torsadé composite allongé et procédé de fabrication d'un tel élément Active EP3553213B1 (fr)

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GB1806046.7A GB2569832B (en) 2018-04-12 2018-04-12 Improvements in or relating to polymer materials

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EP3553213A3 EP3553213A3 (fr) 2020-02-26
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JP2026059696A (ja) * 2024-09-26 2026-04-07 ライトルート・カンパニー・リミテッド 二次電池用廃分離膜をリサイクルした原糸

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Publication number Publication date
EP3553213A3 (fr) 2020-02-26
GB2569832A (en) 2019-07-03
GB201806046D0 (en) 2018-05-30
EP3553213A2 (fr) 2019-10-16
GB2569832B (en) 2020-10-21

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