FLEXIBLE SHEET-LIKE MATERIAL FOR BOUNDING A MATRIX MATERIAL FEED SPACE AND METHOD FOR THE PRODUCTION THEREOF

Abstract

The flexible sheet-like material comprises a textile layer, which is coated at least on one side with a functional layer which is permeable to gas but impermeable to the matrix material, acting as a barrier layer for the matrix material, and is produced by coating the textile layer directly with a foam or a paste.

Claims

1. A process for the vacuum assisted production of fibre-reinforced plastics material components from composite fibre semi-finished products which are arranged in a matrix material feed space, the process comprising: defining the matrix material feed space with a flexible sheet-like material, wherein the flexible sheet-like material comprises a textile layer which is coated on at least one side with a function layer that is permeable to gas but impermeable to matrix material, the flexible sheet-like material acts as a barrier layer for the matrix material, and the flexible sheet-like material is produced by coating the textile layer with a foam or a paste; and drawing a matrix material by suction from an external resin container into the matrix material feed space.

2. The process according to claim 1, wherein the textile layer is a woven fabric, an interlaced fabric, a knitted fabric, a non-woven fabric or a felt and at least mainly consists of one or more of the following materials: polyester, polyamide, aramid, glass fibres, polyacrylic, polypropylene, polyethylene, viscose, cellulose, cotton.

3. The process according to claim 1, wherein the function layer is produced from a foam or a paste which is produced from an aqueous polymer dispersion with at least mainly one or more of the following substances: polyurethane, fluoropolymers, acrylate, styrene acrylate, nitrile-butadiene latex, styrene-butadiene latex, ethylene vinyl acetate, polyvinyl acetate, silicone, copolymers of the above-mentioned substances, further additives.

4. The process according to claim 1, wherein the function layer is produced from a paste which is produced from a solvent-containing polymer with at least mainly one or more of the following substances: polyurethane, fluoropolymers, acrylate, styrene acrylate, nitrile-butadiene latex, styrene-butadiene latex, ethylene vinyl acetate, polyvinyl acetate, silicone, copolymers of the above-mentioned substances, further additives.

5. A process for the vacuum assisted production of fibre-reinforced plastics material components from composite fibre semi-finished products which are arranged in a matrix material feed space, the process comprising: defining the matrix material feed space with a flexible sheet-like material, wherein the flexible sheet-like material comprises a textile layer which is coated on at least one side by a coating process with a gas-permeable but matrix material-impermeable foam layer or paste layer which forms a barrier layer for a matrix material; and drawing a matrix material by suction from an external resin container into the matrix material feed space.

6. The process according to claim 5, wherein the foam layer or paste layer is compressed by a calendering device at elevated temperature and elevated pressure to influence in a targeted manner the gas-permeability and/or matrix material-impermeability characteristics of the sheet-like material.

7. The process according to claim 5, wherein the textile layer is coated with a foam or a paste based on an aqueous polymer dispersion, the foam or paste being produced at least mainly from one or more of the following substances: polyurethane, fluoropolymers, acrylate, styrene acrylate, NBR, SBR, ethylene vinyl acetate, polyvinyl acetate, silicone, copolymers of the above-mentioned substances, further additives.

8. The process according to claim 7, wherein when applied to the textile layer, the foam has a weight of 100-900 g/l, the dry layer weight being 10-120 g/m.sup.2.

9. The process according to claim 7, wherein when applied to the textile layer, the foam has a weight of 200-350 g/l, the dry layer weight being 30-40 g/m.sup.2.

10. The process according to claim 7, wherein the textile layer is coated with an aqueous paste, the dry layer weight thereof being 10-120 g/m.sup.2.

11. The process according to claim 7, wherein the textile layer is coated with an aqueous paste, the dry layer weight thereof being 35-45 g/m.sup.2.

12. The process according to claim 5, wherein the textile layer is coated with a paste based on a solvent-containing polymer, the paste being produced at least mainly from one or more of the following substances: polyurethane, fluoropolymers, acrylate, styrene acrylate, nitrile-butadiene latex, styrene-butadiene latex, ethylene vinyl acetate, polyvinyl acetate, silicone, copolymers of the above-mentioned substances, further additives.

13. The process according to claim 12, wherein the textile layer is coated with a solvent-containing paste, the dry layer weight thereof being 10-120 g/m.sup.2.

14. The process according to claim 12, wherein the textile layer is coated with a solvent-containing paste, the dry layer weight thereof being 40-50 g/m.sup.2.

15. The process according to claim 12, wherein before the textile layer is coated, it is pretreated with additives which are produced from aqueous or organic solutions and comprise one or more of the following substances: fluorocarbon resins, impregnating resins, surfactants, silica sol derivatives, bonding agents.

16. The process according to claim 5, wherein a coagulation coating of the textile layer with an aqueous dispersion paste, a foam or a solvent-based paste, and before the textile layer is coated, electrolyte salts, chemical additives or ionic differential additives are applied thereon to produce precipitation reactions in the coating material.

17. The process according to claim 5, wherein by a coagulation coating of the textile layer with an aqueous dispersion paste, a foam or a solvent-based paste, the coated sheet-like material being subjected to a subsequent after-treatment by alkalization or acid elimination from aqueous liquors to produce a porosity in the polymer film.

18. The process according to claim 5, wherein an extraction coating of the textile layer with an aqueous dispersion paste, a foam or a solvent-based paste, the coating material containing additives which are partly or completely extracted again from the coating material by an aftertreatment of the coated sheet-like material.

19. The process according to claim 5, wherein the foam or paste is brought to precipitation/coagulation thermo-sensitively on the textile layer.

20. The process according to claim 5, wherein the foam or paste is brought to precipitation/coagulation due to an instability which arises during drying on the textile layer.

Description

EXAMPLE 1 (Foam)

[0044] Material of textile layer: Polyester woven fabric [0045] Coating material (foam): Polyurethane-based aqueous dispersion with additives [0046] Viscosity of the material to be foamed: 35-45 dPas [0047] Foam weight: 200-240 g/l [0048] Dry layer weight: 35-40 g/m.sup.2 [0049] Calender temperature when pre-chintzing the textile: 170-200° C., in particular 185° C. [0050] Application method: Doctor or stencil coating [0051] Foam drying temperatures: 80-130° C. [0052] Calender temperature during compression: 170-200° C., in particular 180° C.

EXAMPLE 2 (Paste)

[0053] Material of textile layer: Polyester woven fabric [0054] Coating material (paste): Solution of polyurethane with additives to achieve a micro-porosity by coagulation (selective drying) [0055] Viscosity: 35-45 dPas [0056] Dry layer weight: 40-50/m.sup.2 [0057] Calender temperature when pre-chintzing: 170-200° C., in particular 185° C. [0058] Application method: Doctor or stencil coating [0059] Drying/condensation temperature: 20-225° C. [0060] Calender temperature during compression (optional): 120-190° C.