KNITTED STRUCTURE FOR REINFORCING COMPOSITE MATERIALS

Abstract

The object of the invention is a composite product that may include a knitted reinforcing structure, which has at least two skins, connected by links; the link density being between 1 link per 40 square stitches and one link per 10,000 square stitches. The invention also relates to the method for producing composite product obtained that may include between 55 and 85% by volume of polymeric material and between 15 and 45% by volume of reinforcing fibers.

Claims

1. A composite product comprising a resin and a knitted reinforcing structure, the knitted structure having at least two skins (1, 2), connected by links (3); the link (3) density being between one link per 40 square stitches and one link per 10,000 square stitches.

2. The product according to claim 1, characterized in that the knitted structure is produced from a fiber of a reinforcing material chosen from glass, carbon, basalt, quartz, para-aramid, meta-aramid, polypropylene, polyamide, polyethylene terephthalate, polyester, linen, hemp, thermoplastics, such as polyetherimide, polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS).

3. The product according to claim 1, characterized in that the link (3) density is between one link per 100 square stitches and one link per 5,000 square stitches, preferably between one link per 200 square stitches and one link per 1,000 square stitches.

4. The product according to claim 1, characterized in that the knitted structure is obtained by a weft knitting technique.

5. The product according to claim 1, characterized in that the knitted structure is obtained by a rectilinear weft knitting technique.

6. The product according to claim 1, characterized in that the knitted structure has a three-dimensional shape adapted to the shape of the composite product.

7. The product according to claim 1, comprising between 55 and 85% by volume of resin, in particular polymeric material and between 15 and 45% by volume of reinforcing fibers.

8. The product according to claim 1, characterized in that the polymeric material is chosen from thermoplastic materials such as polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, polyetheretherketone (PEEK), polyetherketoneketone (PEKK) and thermosets such as polyester and epoxy.

9. A method for manufacturing a composite product, characterized in that it comprises the following steps: manufacture of a knitted structure according to claim 1, impregnation of the knitted structure according to an impregnation method with polymeric material, consolidation of the composite product.

10. The manufacturing method according to claim 9, characterized in that the polymeric material is thermoplastic material, the consolidation step being carried out by melting the thermoplastic material.

11. The manufacturing method according to claim 9, characterized in that the polymeric material is thermosetting material, the consolidation step being carried out by polymerization of the thermosetting material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Embodiments are illustrated by way of example and are not limited in the accompanying figures. In the figures below, the representations are not necessarily to scale.

[0019] FIG. 1 represents a schematic sectional view of a comparative knitted reinforcing structure 100.

[0020] FIG. 2 is a photo of such a comparative structure 100.

[0021] FIG. 3 represents a schematic sectional view of a knitted reinforcing structure 300 according to particular embodiments of the invention.

[0022] FIG. 4 represents a photo of such a knitted structure 300 according to the invention.

[0023] FIG. 5 is the stitch diagram 500 of a first exemplary embodiment.

[0024] FIG. 6 is the stitch diagram 600 of a second exemplary embodiment.

[0025] Skilled artisans appreciate that elements in the figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help to improve understanding of embodiments of the invention. Further, the use of the same reference symbols in different drawings indicates similar or identical items.

DETAILED DESCRIPTION

[0026] According to particular embodiments, a particular knitting technique may be used to create a reinforcement for composite products which may have a very high compressibility.

[0027] According to yet other embodiments, the present invention relates to composite products that may include a resin matrix and a knitted reinforcing structure, which may have at least two skins, a front skin and a back skin, the at least two skins being connected by occasional links; the link density being between one link per 40 square stitches and one link per 10,000 square stitches.

[0028] For purposes of embodiments described herein, the link density may be defined by considering, for a surface of the knitted structure, the number of rows (X) multiplied by the number of columns (Y) and by counting the number of links (Z) created on this surface. A number of links are obtained per square stitch.

[0029] According to still other embodiments, the knitted structure may be, for example, made from a yarn of a reinforcing material chosen from glass, carbon, basalt, quartz, para-aramid, meta-aramid, polypropylene, polyamide, polyethylene terephthalate, polyester, flax, hemp, as well as thermoplastic materials such as polyetherimide, polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS); the kind will be chosen as a function of the melting point thereof which must be greater than the melting point of the resin constituting the matrix of the final composite product.

[0030] According to a particular embodiment, the knitted structure also may include an intermediate skin.

[0031] Advantageously, the link density of the structure may be between 1 link per 100 square stitches and one link per 5,000 square stitches, preferably between 1 link per 200 square stitches and one link per 1,000 square stitches.

[0032] According to a particular embodiment, the structure may be obtained by a weft knitting technique. According to certain embodiments, it may be a rectilinear or circular weft knitting method, preferably the rectilinear weft knitting technique may be used. This technique may have the advantage of making it easier to obtain complex 3D shapes than with the circular knitting technique.

[0033] According to a particular embodiment, the structure may have a jersey arrangement. However, the invention can be produced with any contextures (locknit, little dive, ringlet, openwork, knotted, etc.). The compressibility may be provided by the link density and not by the type of contexture.

[0034] Advantageously, the structure may have a three-dimensional structure adapted to the shape of the final composite product.

[0035] According to other embodiments, the basis weight of the knitted structure may be preferably between 200 to 4,000 g/m.sup.2, more preferably between 800 and 2,000 g/m.sup.2.

[0036] According to still other embodiments, the thickness of the knitted reinforcing structure may be preferably between 1 and 6 mm, more preferably between 2 and 4 mm, without presuming its final thickness after compression.

[0037] According to yet other embodiments, the composite product reinforced with a knitted structure may include, in particular, between 50 and 85% by volume of polymeric material, preferably between 55 and 80%, and more preferably between 60 and 75% and between 15 and 50% by volume of reinforcing fibers, preferably between 20 and 45%, more preferably between 25 and 40%. According to a particular embodiments, the polymeric material may be chosen from thermoplastic materials such as polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, polyetheretherketone (PEEK), polyetherketoneketone (PEKK) and thermosets such as polyester and epoxy.

[0038] The present invention also may relate to a method of manufacturing a composite product, which may include the following steps: [0039] manufacture of a knitted structure according to the above features, [0040] impregnation of the knitted structure using a method of infusion at room temperature, with polymeric material having a melting point that may be lower than the melting point of the knitted reinforcement; [0041] consolidation of the composite product by melting the thermoplastic material or by polymerization of the thermosetting material.

[0042] In particular embodiments, the knitted structure may have a complex 3D shape, similar or adapted to the final shape of the composite product.

[0043] According to other embodiments, a multi-wall knit can be produced by knitting several layers simultaneously.

[0044] According to another embodiment, the structure can be obtained by a warp knitting method. According to still other embodiments, the structure can be obtained by a ‘multi-beam’ knit.

[0045] According to still other embodiments, a beam carries a set of warp yarn which will form a skin. Therefore, one beam per skin may be needed.

[0046] Weft knitting can involve a double needle bed knitting with point links: ˜1 per 100 square stitches (i.e., nearly 200 times less than the standard solution according to Example 1).

[0047] According to a second embodiment, the preform can be produced by knitting a reinforcing yarn, the polymeric material being introduced in a liquid form into a mold. According to a first embodiment, the preform can be produced by knitting a mixed yarn comprising polymeric material and reinforcing material.

[0048] The following examples illustrate the particular embodiments of the invention in a non-limiting manner.

[0049] Many different aspects and embodiments are possible. Some of those aspects and embodiments are described herein. After reading this specification, skilled artisans will appreciate that those aspects and embodiments are only illustrative and do not limit the scope of the present invention. Embodiments may be in accordance with any one or more of the embodiments as listed below.

Embodiment 1

[0050] A composite product comprising a resin and a knitted reinforcing structure, the knitted structure having at least two skins (1, 2), connected by links (3); the link (3) density being between one link per 40 square stitches and one link per 10,000 square stitches.

Embodiment 2

[0051] The product according to embodiment 1, characterized in that the knitted structure is produced from a fiber of a reinforcing material chosen from glass, carbon, basalt, quartz, para-aramid, meta-aramid, polypropylene, polyamide, polyethylene terephthalate, polyester, linen, hemp, thermoplastics, such as polyetherimide, polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS).

Embodiment 3

[0052] The product according to any one of the preceding embodiments, characterized in that the link (3) density is between one link per 100 square stitches and one link per 5,000 square stitches, preferably between one link per 200 square stitches and one link per 1,000 square stitches.

Embodiment 4

[0053] The product according to any one of the preceding embodiments, characterized in that the knitted structure is obtained by a weft knitting technique.

Embodiment 5

[0054] The product according to any one of the preceding embodiments, characterized in that the knitted structure is obtained by a rectilinear weft knitting technique.

Embodiment 6

[0055] The product according to any one of the preceding embodiments, characterized in that the knitted structure has a three-dimensional shape adapted to the shape of the composite product.

Embodiment 7

[0056] The product according to any one of the preceding embodiments, comprising between 55 and 85% by volume of resin, in particular polymeric material and between 15 and 45% by volume of reinforcing fibers.

Embodiment 8

[0057] The product according to any one of the preceding embodiments, characterized in that the polymeric material is chosen from thermoplastic materials such as polycarbonate, polypropylene, polyamide, polyurethane, PMMA, low density polyethylene terephthalate, polyetherimide, polyetheretherketone (PEEK), polyetherketoneketone (PEKK) and thermosets such as polyester and epoxy.

Embodiment 9

[0058] A method for manufacturing a composite product, characterized in that it comprises the following steps: [0059] manufacture of a knitted structure according to any one of embodiments 1 to 6, [0060] impregnation of the knitted structure according to an impregnation method with polymeric material, [0061] consolidation of the composite product.

Embodiment 10

[0062] The manufacturing method according to any one of the preceding embodiments, characterized in that the polymeric material is thermoplastic material, the consolidation step being carried out by melting the thermoplastic material.

Embodiment 11

[0063] The manufacturing method according to embodiment 9, characterized in that the polymeric material is thermosetting material, the consolidation step being carried out by polymerization of the thermosetting material.

EXAMPLES

[0064] The concepts described herein will be further described in the following Examples, which do not limit the scope of the invention described in the claims.

Example 1 (Comparative)

[0065] double needle bed knitting with regular links between the two needle beds.

[0066] A knitted reinforcing structure according to this method is illustrated in FIGS. 1 and 2. As shown in FIG. 1, a knitted reinforcing structure 100 produced using a double needle bed machine has a front skin 110 and a back skin 120. The yarn used is fiberglass. Link fibers (i.e., links) 130 are arranged regularly and around 2 links per stitch.

[0067] The basis weight is 2897 g/m.sup.2.

[0068] The number of rows/cm is 4.6483; the number of columns/cm is 3.7692.

[0069] The advantage of such a reinforcement according to the prior art is that it is stable because it is balanced between the front skin and the back skin.

[0070] The disadvantage of such a reinforcement is that the links act like beams which limit the compressibility of the material. If the vacuum/pressure conditions are not sufficient when injecting the plastic material, the resulting composite material is thicker. The resulting volume properties are lower. The composite material is either heavier or more porous, which further reduces the mechanical properties thereof.

[0071] A composite product is produced by impregnating the knitted reinforcement with polyester resin using an infusion method at room temperature.

[0072] The amount of fibers is 24% by volume per 76% by volume of resin.

[0073] Tensile tests are carried out.

[0074] The properties obtained are: a Young's modulus of 3.7-4.8 GPa and a tear strength of 46-57 MPa.

Example 2 (Comparative)

[0075] single needle bed knitting.

[0076] A knitted reinforcing structure is produced with a glass yarn. Only one needle bed is used. According to this method, the reinforcement is fine and has good volume properties because it is dense.

[0077] The disadvantages are that the reinforcement is unstable because it is not balanced between the front and the back. It rolls over on itself. The production of the composite product is more complicated because the reinforcement requires time to be stabilized/fixed during the draping into a mold.

Example 3 (According to an Embodiment of the Invention)

[0078] double needle bed knitting with spaced links between the two needle beds.

[0079] A knitted reinforcing structure 300 is produced using a double needle bed machine so as to obtain a front skin 310 and a back skin 320. The yarn used is fiberglass.

[0080] The links 340 between the two skins are made by a known load-linking technique. This technique consists of carrying out, for each link, a half-rise of a needle of one of the two needle beds, which causes the fiber to grip without forming a stitch. The link density is around 1 per 45 square stitches.

[0081] FIG. 5 illustrates the knit obtained.

[0082] The two skins are independent except at the link points. In this exemplary embodiment, the skins are made in jersey. The link is made by loading the fiber from skin 1 into skin 2.

[0083] The basis weight is 2868 g/m.sup.2.

[0084] The thickness is 3 mm at rest.

[0085] The number of rows/cm is 4.4079; the number of columns/cm is 3.8569.

[0086] A composite product is produced by impregnating the knitted reinforcing structure with polyester resin using an infusion method at room temperature.

[0087] The amount of fibers is 34% by volume per 66% by volume of resin.

[0088] Tensile tests are carried out.

[0089] The properties obtained are: a Young's modulus of 7 to 8 GPa and a tear strength of 80 to 90 MPa.

Example 4 (According to an Embodiment of the Invention)

[0090] double needle bed knitting with spaced links between the two needle beds.

[0091] Link per one stitch.

[0092] FIG. 6 illustrates the production of a knitted reinforcing structure comprising two skins and links. The link density is around 1 per 45 square stitches.

[0093] The yarn used is of the glass type.

[0094] The two skins are independent except at the link points. Here the skins are made in jersey. The link is made by a stitch of the fiber of skin 1 on the opposite needle bed. At this point, to keep an equal number of stitches between the two skins, no stitch is knitted (floated) in skin 2.

[0095] The basis weight is 2868 g/m.sup.2.

[0096] The thickness is 3 mm at rest.

[0097] The number of rows/cm is 4.4079; the number of columns/cm is 3.8569.

[0098] A composite product is produced by impregnating the knitted reinforcing structure with polyester resin using an infusion method at room temperature.

[0099] The amount of fibers is 34% by volume per 66% by volume of resin.

[0100] Tensile tests are carried out.

[0101] The properties obtained are: a Young's modulus of 7 to 8 GPa and a tear strength of 80 to 90 MPa.

[0102] The knitted reinforcing structures of the composite products according to the present invention have many advantages:

[0103] The reinforcing structure is stable because it is balanced between the front skin and the back skin. It can be set up easily and quickly.

[0104] The reinforcing structure is very compressible with good volume properties because it is dense.

[0105] A reinforcing structure may include two skins gives the final product properties equivalent to two single needle bed reinforcing structures; hence a reduction in the draping time.