Process for the manufacture of a multilayer material sheet, multilayer material sheet and use hereof

Patent metadata

Field	Value
Publication number	US-10315380-B2
Application number	US-201013515936-A
Country	US
Kind code	B2
Filing date	Dec 16, 2010
Priority date	Dec 17, 2009
Publication date	Jun 11, 2019
Grant date	Jun 11, 2019

Abstract

The invention relates to a process for the manufacture of a multilayer material sheet comprising unidirectional high performance fibers, the process comprising the steps of positioning the fibers in a parallel fashion, consolidation of the fibers to obtain a monolayer, stacking at least two monolayers such that the fiber direction in one monolayer is at an angle α to the direction of the fibers in an adjacent monolayer and fixation whereby the stack of at least two monolayers is subjected to a pressure and temperature treatment for a duration of a least 2 seconds, followed by cooling the stack under pressure to a temperature of 120° C. or lower. The invention furthermore relates to the multilayer material sheet obtainable with the process according to the invention. This multilayer material sheet has a reduced uptake of liquids.

First claim

The invention claimed is:

1. A process for the manufacture of a multilayer material sheet comprising unidirectional high performance fibers with a tensile strength of at least 1.0 GPa and a tensile modulus of at least 40 GPa, the process comprising the steps of:
(a) positioning the fibers in a parallel fashion,
(b) consolidating the parallel fibers to obtain a monolayer by embedding at least a part of the fibers in a matrix material which is present in an amount of less than 20 wt. % based on the total weight of the monolayer,
(c) stacking at least two monolayers such that a fiber direction in one monolayer is at an angle α relative to a direction of the fibers in an adjacent monolayer to thereby form a continuous stack, and
(d) fixating the continuous stack of at least two monolayers formed by step (c) using a belt press which subjects the continuous stack of at least two monolayers for a duration of at least 2 seconds to a pressure treatment at a pressure of at least 0.5 MPa and a temperature treatment at a temperature below a melting point or degradation temperature of the fibers to thereby form a pressure and temperature treated stack of at least two fixed monolayers, and thereafter
(e) subjecting the pressure and temperature treated stack of at least two fixed monolayers formed by step (d) to controllable rapid cooling under pressure to cool the stack of at least two fixed monolayers from the melting point or degradation temperature of the fibers to a temperature of 80° C. or lower within at least 2 seconds to less than 120 seconds.

2. The process according to claim 1 , wherein step (d) is practiced at a temperature of 85 to 135° C.

3. The process of claim 1 , wherein the high performance fibers are high performance polyolefin fibers.

4. The process of claim 3 , wherein the high performance polyolefin fibers are obtained by a gel spinning process.

5. The process of claim 3 , wherein the high performance polyolefin fibers are high performance polyethylene fibers.

6. The process of claim 1 , wherein the high performance fibers are aramid fibers.

7. The process according to claim 1 , wherein step (e) includes subjecting the pressure and temperature treated stack of at least two fixed monolayers formed by step (d) to controllable rapid cooling under pressure using the belt press.

8. The process according to claim 1 , wherein the pressure treatment during fixation according to step (d) is done under isobaric conditions.

9. The process according to claim 1 , wherein step (b) is practiced by embedding at least part of the fibers in less than 15 wt %, based on the total weight of the monolayer, of the matrix material.

Assignees

• Van Putten Koen
• Wilms Johannes Maria Mathias
• Van Klinken Ernst Jan
• Van Der Werff Harm
• Nielaba Leonard Josef Arnold
• Marissen Roelof
• Dsm Ip Assets Bv

Inventors

• Van Putten Koen
• Wilms Johannes Maria Mathias
• Van Klinken Ernst Jan
• Van Der Werff Harm
• Nielaba Leonard Josef Arnold
• Marissen Roelof

Classifications

• B32B2260/023

  Two or more layers · CPC title

• B32B37/1027

  Pressing using at least one press band · CPC title

• B32B2262/0253

  Polyolefin fibres · CPC title

• B32B2250/20

  All layers being fibrous or filamentary · CPC title

• B32B5/12 Primary

  characterised by the relative arrangement of fibres or filaments of {different layers, e.g. the fibres or filaments being parallel or perpendicular to each other} · CPC title