MULTILAYER COMPOSITE COMPOSITION, ITS MANUFACTURING PROCESS, AND ARTICLE OBTAINED THEREOF

Abstract

The present invention relates to a multilayer composition comprising a surface layer comprising a thermoplastic polymer A and a substrate layer comprising a polymeric composite material based thermoplastic (meth)acrylic matrix and a fibrous material as reinforcement. The multilayer composition is suitable for mechanical or structured parts or articles with a decorative surface aspect. The present invention concerns also a manufacturing process for multilayer mechanical or structured parts or articles and three-dimensional mechanical or structured parts.

Claims

1. A multilayer mechanical or structural wind turbine part comprising a) a layer comprising a polymer A, and b) a layer B comprising a polymeric composite material wherein the layers a) and b) are adhered together, and wherein said polymeric composite material comprises a polymeric thermoplastic (meth)acrylic matrix and a fibrous material as reinforcement wherein the fibrous material comprises either a fiber with an aspect ratio of the fiber of at least 1000 or the fibrous material has a two dimensional macroscopic structure.

2. The multilayer mechanical or structural wind turbine part of claim 1, wherein said polymer A is a thermoplastic polymer.

3. The multilayer mechanical or structural wind turbine part of claim 1, wherein said polymer A is a thermoset polymer.

4. The multilayer mechanical or structural wind turbine part of claim 1, wherein said layers are adhered without any added adhesive.

5. The multilayer mechanical or structural wind turbine part of claim 1, wherein said layers are laminated using heat and/or pressure.

6. The multilayer mechanical or structural wind turbine part of claim 1, wherein said polymer A is a thermoplastic composite material of the same or different composition as thermoplastic composite material B.

7. The multilayer mechanical or structural wind turbine part of claim 1, further comprising an additional thermoplastic composite layer adhered to the opposite side of the polymer A layer.

8. The multilayer mechanical or structural wind turbine part of claim 5, wherein the first thermoplastic composite layer and the second thermoplastic layer have the same composition.

9. The multilayer mechanical or structural wind turbine part of claim 5, wherein the first thermoplastic composite layer and the second thermoplastic composite layer have different compositions.

10. The multilayer composition according to claim 1, wherein the polymer A and is selected from the group consisting of: (Meth)acrylic polymers saturated polyester (PET, PBT, PLA etc.); ABS (acrylonitrile-butadiene-styrene copolymer); SAN (styrene-acrylonitrile copolymer); ASA (acrylic-styrene-acrylonitrile copolymer); polystyrene (crystalline or high-impact); polypropylene (PP); polyethylene (PB); polycarbonate (PC); PPO; polysulfone; PVC (polyvinylchloride); PVDF (polyvinylidene fluoride) chlorinated PVC (PVCC); PU (polyurethane) or mixtures thereof.

11. A method for forming a multilayer mechanical or structural wind turbine part comprising, a) stacking at least one first thermoplastic composite layer A, at least one middle thermoplastic layer B, and at least one second thermoplastic composite layer C, wherein at least one of said first or second thermoplastic composite layer comprises a polymeric thermoplastic (meth)acrylic matrix and a fibrous material as reinforcement wherein the fibrous material comprises either a fiber with an aspect ratio of the fiber of at least 1000 or the fibrous material has a two dimensional macroscopic structure, b) laminating said stack of at least three layers, using heat and pressure, to form a multilayer mechanical or structural wind turbine part.

12. The method of claim 10, wherein said lamination occurs in a closed mold.

13. The method of claim 10, wherein said multi-layer part is further thermoformed and transformed into a final wind turbine part.

14. The method of claim 12, wherein said multilayer mechanical or structural wind turbine part is further combined and adhered to at least one other mechanical or structural wind turbine part.

15. A method for assembling a wind turbine part comprising the steps of a) positioning a first wind turbine part as claimed in claim 1, adjacent to a second wind turbine part comprising a thermoplastic fiber-reinforced composite, wherein said polymer A is a thermoplastic an is between the two different thermoplastic composites, and b) laminating said multilayer structure together using heat and/or pressure to adhere the adjacent parts together.

Description

FIGURES

[0224] FIG. 1

[0225] Multi layer composition according to one aspect of the invention with a surface layer (1) comprising a thermoplastic polymer A and the substrate layer (2) comprising a polymeric composite material.

[0226] FIG. 2

[0227] Multilayer composition according to another aspect of the invention with a surface layer (1) comprising a thermoplastic polymer A and the substrate layer (2) comprising a polymeric composite material characterized and an additional intermediate layer (3) between the surface layer (1) and the substrate layer (2), said intermediate later comprises a thermoplastic polymer B.

EXAMPLES

[0228] A multilayer composition is realized according to the structure given in FIG. 2. The surface layer (1) and the intermediate layer (3) are obtained by thermoforming Senosan AM50 from the company SENOPLAST in a mold. The carrier layer of Senosan AM50 consists of an easily thermo-formable and high impact ABS and will give the intermediate layer and the top layer is an impact modified acrylic (PMMA) and will give the surface layer. The substrate layer comprising the polymeric composite material is obtained by polymerizing a methacrylic syrup in the same closed mold after infusion of a fibrous material.

[0229] The syrup is prepared by dissolving 25 parts by weight of the PMMA (BS520 a copolymer of MMA comprising ethyl acrylate as a comonomer) in 75 parts by weight of methyl methacrylate, which is stabilized with MEHQ (hydroquinone monomethyl ether). To the 100 parts by weight of the syrup are added 2 parts by weight of benzoyl peroxide (BPOLuperox A75 from ARKEMA) and 0.2 parts by weight of DMPT (N,N-dimnethyl-p-toluidine from Sigma-Aldrich). The syrup has a dynamic viscosity of 520 mPa*s at 25? C.

[0230] The syrup is infused in a closed mould comprising a sheet of Senosan AM50 with the toplayer toward one mold surface and a glass fabric as fibrous substrate posed on the intermediate ABS layer; the syrup will impregnate the fibrous material. Then the syrup is polymerized at 25? C. during 80 minutes in the mold.

[0231] A multilayer composition according to FIG. 2 is obtained