Door module
The present invention relates to door modules comprising at least one single-layer, continuous fiber-reinforced semifinished fiber matrix product which is obtained by impregnating semifinished fiber products with at least one thermoplastic, and to the use thereof in vehicles or in buildings.
1. A door module comprising at least one single-layer semifinished fiber matrix product comprising
1 to 100 semifinished fiber product plies made of continuous fibers having a basis weight in the range from 5 g/m 2 to 3000 g/m 2 ,
and the entirety of all semifinished fiber product plies has been impregnated with at least one thermoplastic having an MVR to ISO 1133 in the range from 1 cm 3 /10 min to 100 cm 3 /10 min,
wherein the thermoplastic is selected from the group of the polyolefins, vinyl polymers, polyacrylates, polyamides, polyurethanes, polyureas, polyimides, polyesters, polyethers, polystyrenes, polyhydantoins, polyphenylene oxides, polyarylene sulfides, polysulfones, polycarbonates, polyphthalamides, polymethylmethacrylates, styrene-acrylonitriles, olefin-based thermoplastic elastomers, thermoplastic polyurethanes and polyoxymethylenes,
and this semifinished fiber matrix product has a proportion by volume of fiber materials defined according to DIN 1310 in the range from 5% to 90% by volume and a proportion by volume of air or gas of less than 15% by volume.
2. The door module as claimed in claim 1 , wherein the semifinished fiber matrix product has a material thickness in the range from 0.05 mm to 6 mm.
3. The door module as claimed in claim 1 , wherein the thermoplastic comprises the vinyl polymers and wherein said vinyl polymers are selected from the group of polyvinyl halides, polyvinyl esters and polyvinyl ethers.
4. The door module as claimed in claim 1 , wherein the thermoplastic comprises polyolefins and wherein the polyolefins are polyethylene or polypropylene.
5. The door module as claimed in claim 1 , wherein the thermoplastic comprises polyesters and wherein the polyesters are polyethylene terephthalate or polybutylene terephthalate.
6. The door module as claimed in claim 1 , wherein the thermoplastic comprises polycarbonates based on 2,2-bis(4-hydroxyphenyl)propane, bis(4-hydroxyphenyl) sulfone, dihydroxydiphenyl sulfide, tetramethylbisphenol A, 1,1-bis(4-hydroxyphenyl)-3,3,5-trimethylcyclohexane or 1,1,1-tris(4-hydroxyphenyl)ethane.
7. The door module as claimed in claim 1 , wherein the thermoplastic comprises polyphthalamide and wherein the polyphthalamide is PA 6T, PA 10T or PA 12T.
8. The door module as claimed in claim 1 , wherein the polyamides have a relative solution viscosity in m-cresol in the range from 2.0 to 4.0, where the relative solution viscosity η rel is measured to EN ISO 307 in m-cresol at 25° C.
9. The door module as claimed in claim 8 , wherein the thermoplastic comprises polyamide from the group of PA 66, PA 6 and PA 12.
10. The door module as claimed in claim 1 , wherein the thermoplastic further comprises at least one thermal stabilizer.
11. The door module as claimed in claim 10 , wherein the thermal stabilizer is a metal-based thermal stabilizers or an organic thermal stabilizers.
12. The door module as claimed in claim 11 , comprising polyhydric alcohols.
13. The door module as claimed in claim 11 , wherein the thermal stabilizer is a copper stabilizer.
14. A process for producing a door module, comprising:
providing at least one single-layer semifinished fiber matrix product as claimed in claim 1 ,
shaping and curing, in a mold, the single-layer semifinished fiber matrix product whereby the door module is formed, and
removing the door module from the mold.
15. The process as claimed in claim 14 , wherein the shaping is preceded by the process steps of impregnating and consolidating and optionally solidifying the entirety of all semifinished fiber product plies with at least one thermoplastic or with a thermoplastic composition.