PROCESS FOR THE PRODUCTION OF FIBRE-REINFORCED-COMPOSITES
The invention relates a process for preparing a fibre-reinforced composite (K) comprising the following steps: (a) Providing at least one continuous fibrous reinforcement material (A); (b) Providing at least one matrix polymer composition (B) having melt volume-flow rate (MVR (220/10) according to ISO 1133) of 40 to 70 mL/10 min and a viscosity number VN (according to DIN 53726) of 45 to 75 ml/g; (c) Applying the at least one matrix polymer composition (B) to at least one surface of the at least one continuous fibrous reinforcement material (A) to obtain a layered arrangement; (d) Heating the layered arrangement obtained in step (c) to a first temperature (T1) sufficiently above the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B) to obtain a substantially liquid substantially amorphous matrix polymer composition (B); (e) Allowing the substantially liquid matrix polymer composition (B) to impregnate the at least one continuous fibrous reinforcement material (A); (f) Cooling the thus obtained polymer-impregnated continuous fibrous reinforcement material (A) to a second temperature (T2) below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B) in order to obtain a fibre-reinforced composite (K); wherein substantially amorphous matrix polymer composition (B) is a thermoplastic styrene-based substantially amorphous matrix polymer composition (B) and wherein least one of the process steps (d) and/or (e) is carried out at a temperature in the range of 230 to 330° C.
1 - 15 . (canceled)
16 . A process for preparing a fibre-reinforced composite (K) comprising at least the following steps:
(a) providing at least one continuous fibrous reinforcement material (A);
(b) providing at least one substantially amorphous matrix polymer composition (B) having melt volume-flow rate (MVR (220/10) according to ISO 1133) of 40 to 70 mL/10 min, and a viscosity number VN (according to DIN 53726) of 45 to 75 ml/g;
(c) applying the at least one substantially amorphous matrix polymer composition (B) to at least one surface of the at least one continuous fibrous reinforcement material (A) to obtain a layered arrangement;
(d) heating the layered arrangement obtained in step (c) to a first temperature (T1) sufficiently above the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B) to obtain a substantially liquid substantially amorphous matrix polymer composition (B);
(e) allowing the substantially liquid matrix polymer composition (B) to impregnate the at least one continuous fibrous reinforcement material (A); and
(f) cooling the thus obtained polymer-impregnated continuous fibrous reinforcement material (A) to a second temperature (T2) below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B) in order to obtain a fibre-reinforced composite (K);
wherein substantially amorphous matrix polymer composition (B) is a thermoplastic styrene-based substantially amorphous matrix polymer composition (B) and wherein least one of the process steps (d) and/or (e) is carried out at a temperature in the range of 230 to 330° C.
17 . The process for preparing a fibre-reinforced composite (K) according to claim 16 comprising at least the following steps:
(a) providing ≥50 wt.-%, based on the total weight of the fibre-reinforced composite (K), of at least one continuous fibrous reinforcement material (A);
(b) providing <50 wt.-%, based on the total weight of the fibre-reinforced composite (K), of at least one matrix polymer composition (B) comprising
(B1) 60 to 80 wt.-%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene and/or α-methyl styrene and acrylonitrile having a number average molecular weight Mn of 30,000 to 100,000 g/mol; and
(B2) 20 to 40 wt.-%, based on the total weight of the matrix polymer composition (B), of at least one copolymer of styrene, acrylonitrile, maleic anhydride, and/or maleic acid and optionally monomers comprising further chemical functional groups which are appropriate to interact with the surface of the at least one continuous fibrous reinforcement material (A) having a number average molecular weight Mn of 30,000 to 100,000 g/mol;
(c) applying the at least one matrix polymer composition (B) to at least one surface of the at least one continuous fibrous reinforcement material (A) to obtain a layered arrangement;
(d) heating the layered arrangement obtained in step (c) to a first temperature (T1) sufficiently above the glass transition temperature (Tg) of the at least one matrix polymer composition (B) to obtain a substantially liquid matrix polymer composition (B);
(e) allowing the substantially liquid matrix polymer composition (B) to impregnate the at least one continuous fibrous reinforcement material (A); and
(f) cooling the thus obtained polymer-impregnated continuous fibrous reinforcement material (A) to a second temperature (T2) below the glass transition temperature (Tg) of the at least one matrix polymer composition (B) in order to obtain a fibre-reinforced composite (K);
wherein the at least one matrix polymer composition (B) has a glass transition temperature (Tg) in the range of 100° C. to 150° C., a melt volume-flow rate (MVR (220/10) according to ISO 1133) of 40 to 70 mL/10 min, and a viscosity number VN (according to DIN 53726) of 45 to 75 ml/g.
18 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein the first temperature (T1) is in the range of 1 to 200° C., above glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B) and the second temperature (T2) is in the range of 1 to 50° C. below the glass transition temperature (Tg) of the at least one substantially amorphous matrix polymer composition (B).
19 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein the first temperature (T1) is in the range of 180° C. to 300° C.
20 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein the second temperature (T2) is in the range of 70° C. to 100° C.
21 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein at least one of the process steps (d) to (f) is carried out under increased pressure.
22 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein at least the process step (f) is carried out under increased pressure, and the increased pressure is applied in step (f) until the second temperature (T2) is reached.
23 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein the at least one substantially amorphous matrix polymer composition (B) comprises >0 and 3 wt.-%, of repeating units derived from monomer moieties which are appropriate to interact with the surface of the fibrous reinforcement material (A).
24 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein the at least one continuous fibrous reinforcement material (A) is at least one laminar structure (S) selected from the group consisting of a non-crimp fabric, a woven fabric, a mat, a non-woven fabric, and a knitted fabric.
25 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein 1 to 12 laminar structures (S) are used as the at least one continuous fibrous reinforcement material (A).
26 . The process for preparing a fibre-reinforced composite (K) according to claim 17 , wherein 1 to 10 laminar structures (S) of a woven or non-crimped fabric and additionally at least one laminar structure (S) of a non-woven fabric are used as the at least one continuous fibrous reinforcement material (A), at least one laminar structure (S) of a non-woven fabric being positioned on the top and or bottom of the 1 to 10 laminar structures (S) of a woven or non-crimped fabric.
27 . The process for preparing a fibre-reinforced composite (K) according to claim 26 , wherein least one laminar structure (S) of a non-woven fabric comprises amorphous matrix polymer composition (B) in form of a powder or granules.
28 . The process for preparing a fibre-reinforced composite (K) according to claim 16 , wherein the at least one fibre reinforcement material (A) constitutes 35 to 55 vol.-% of the entire fibre-reinforced composite (K).
29 . A fibre-reinforced composite (K) prepared by a process according to claim 16 .
30 . A molded body (M), optionally having carbon-fibre look, prepared by thermoforming a fibre-reinforced composite (K) according to claim 29 .