Thermoplastic fibre, hybrid yarn, fibre perform and method for producing fibre performs for fibre composite components, in particular high performance fibre composite component, using the same, fibre composite component and method for producing fibre composite components, in particular high performance fibre composite components

Abstract

A thermoplastic fiber comprises a core constructed of a first material, a shell positioned to surround the core and constructed of a second material, and magnetic particles that are ferromagnetic and/or ferrimagnetic particles where the particles are either mainly, almost exclusively, or exclusively arranged in the shell. A fiber perform or semifinished textile product includes at least one thermoplastic fiber. A hybrid yarn comprises reinforcement fibers, thermoplastic fibers, and at least some of the plurality of thermoplastic fibers include at least proportionately ferromagnetic and/or ferrimagnetic particles.

1 . A thermoplastic fiber comprising:
 a core, said core being constructed of a first material;   a shell, said shell being positioned to surround said core, said shell being constructed of a second material; and   magnetic particles, said magnetic particles being one of ferromagnetic particles and ferrimagnetic particles, said magnetic particles also being one of mainly arranged in said shell, almost exclusively arranged in said shell, and exclusively arranged in said shell.   
     
     
         2 . The thermoplastic fiber of  claim 1  wherein said core is round. 
     
     
         3 . The thermoplastic fiber of  claim 1  wherein said shell is round. 
     
     
         4 . The thermoplastic fiber of  claim 1  wherein said first material and said second material are identical. 
     
     
         5 . The thermoplastic fiber of  claim 1  wherein said first material and said second material are different. 
     
     
         6 . The thermoplastic fiber of  claim 1  wherein the diameter of individual said particles is in a range of about 10 nm to about 20 nm. 
     
     
         7 . The thermoplastic fiber of  claim 1  wherein the diameter of individual said particles is about 13 nm. 
     
     
         8 . The thermoplastic fiber of  claim 1  further comprising:
 said particles being in agglomerates of particles; and 
 said agglomerates of particles being in the range of about 100 nm to about 200 nm. 
 
     
     
         9 . The thermoplastic fiber of  claim 1  further comprising:
 said particles being in agglomerates of particles; and 
 said agglomerates of particles being on the order of about 150 nm. 
 
     
     
         10 . The thermoplastic fiber of  claim 1  wherein said fiber comprises at least one of polyetherketone, polyetheretherketone (PEEK), polyphenylene sulphide (PPS), polymide, polyetherimide (PEI), polysulfone (PSU), and polyethersulfone (PES). 
     
     
         11 . The thermoplastic fiber of  claim 1  wherein said fiber is unstretched. 
     
     
         12 . The thermoplastic fiber of  claim 1  wherein said particles are iron oxide modified. 
     
     
         13 . The thermoplastic fiber of  claim 1  wherein said core has a diameter, said diameter being in the range of about 5 μm to about 60 μm. 
     
     
         14 . The thermoplastic fiber of  claim 1  wherein said shell has a thickness in a range of about 0.1 μm to about 20 μm. 
     
     
         15 . The thermoplastic fiber of  claim 1  wherein a concentration of said particles in said shell is in a range of about 10 weight percent to about 50 weight percent. 
     
     
         16 . The thermoplastic fiber of  claim 1  wherein a viscosity thereof is in a range of about 100 to about 1000 Pa·s. 
     
     
         17 . A hybrid yarn comprising:
 a plurality of reinforcement fibers;   a plurality of thermoplastic fibers; and   at least some of the plurality of thermoplastic fibers include at least proportionately ferromagnetic and/or ferrimagnetic particles.   
     
     
         18 . The hybrid yarn of  claim 17  wherein said yarn is suited for the thermal fixing of fiber preforms for, endless fiber reinforced, fiber composite components, and in particular high performance fiber composite components. 
     
     
         19 . The hybrid yarn of  claim 17  wherein at least one of said ferromagnetic particles and said ferrimagnetic particles are in the nanometer range. 
     
     
         20 . The hybrid yarn of  claim 17  wherein said thermoplastic fibers are round. 
     
     
         21 . The hybrid yarn of  claim 17 , wherein said reinforcement fibers are round. 
     
     
         22 . The hybrid yarn of  claim 17  further comprising:
 said reinforcement fibers are round; 
 said thermoplastic fibers respectively include a core, said core having a first material; and 
 a shell surrounding said core, said shell having a second material. 
 
     
     
         23 . The hybrid yarn of  claim 17  further comprising:
 said reinforcement fibers are round; 
 said thermoplastic fibers respectively include a core, said core having a first material; 
 a shell surrounding said core, said shell having a second material; and 
 said first material and said second material are identical. 
 
     
     
         24 . The hybrid yarn of  claim 17  further comprising:
 said reinforcement fibers are round; 
 said thermoplastic fibers respectively include a core, said core having a first material; 
 a shell surrounding said core, said shell having a second material; and 
 said first material and said second material are different. 
 
     
     
         25 . The hybrid yarn of  claim 17  wherein said magnetic particles are one of mainly arranged in said shell, almost exclusively arranged in said shell, and exclusively arranged in the shell. 
     
     
         26 . The hybrid yarn of  claim 17  wherein the diameter of said individual particles is in a range of about 10 nm to about 20 nm. 
     
     
         26 . The hybrid yarn of  claim 17  wherein the diameter of said individual particles is on the order of about 13 nm. 
     
     
         27 . The hybrid yarn of  claim 17  wherein said particles are in agglomerates of particles, said agglomerates of particles being in a range of about 100 nm to about 200 nm. 
     
     
         28 . The hybrid yarn of  claim 17  wherein said particles are in agglomerates of particles, said agglomerates of particles being on the order of about 150 nm. 
     
     
         29 . The hybrid yarn of  claim 17  wherein said reinforcement fibers include anorganic fibers. 
     
     
         30 . The hybrid yarn of  claim 29  wherein said reinforcement fibers are at least one of carbon, glass, synthetic polymers, and aramid. 
     
     
         31 . The hybrid yarn of  claim 17  wherein said thermoplastic fibers include at least one of polyetherketone, polyetheretherketone (PEEK), polyphenylene sulphide (PPS), polyimide, particular polyetherimide (PEI), polysulfone (PSU), and polyethersulfone (PES). 
     
     
         32 . The hybrid yarn of  claim 17  wherein said thermoplastic fibers are unstretched. 
     
     
         33 . The hybrid yarn of  claim 17  wherein said particles are ion oxide modified. 
     
     
         34 . The hybrid yarn of  claim 17  wherein said reinforcement fibers and said thermoplastic fibers are homogeneously mixed. 
     
     
         35 . The hybrid yarn of  claim 17  wherein the diameter of said reinforcement fibers is in a range of about 5 μm to about 15 μm. 
     
     
         36 . The hybrid yarn of  claim 17  wherein the fiber volume content of said reinforcement fibers is in a range of about 50 volume percent to about 70 volume percent. 
     
     
         37 . A fiber preform or semifinished textile product comprising:
 at least one thermoplastic fiber, said thermoplastic fiber having a core, said core being constructed of a first material, a shell, said shell being positioned to surround said core, said shell being constructed of a second material, and magnetic particles, said magnetic particles being ferromagnetic and/or ferrimagnetic particles; and   said magnetic particles being one of mainly arranged in said shell, almost exclusively arranged in said shell, and exclusively arranged in said shell.   
     
     
         38 . A fiber preform or semifinished textile product comprising:
 a hybrid yarn, said hybrid yarn having a plurality of reinforcement fibers, a plurality of thermoplastic fibers; and   at least some of said plurality of thermoplastic fibers include at least one of proportionately ferromagnetic particles and ferrimagnetic particles.   
     
     
         39 . A fiber preform or semifinished textile product comprising:
 at least one thermoplastic fiber, said thermoplastic fiber having a core, said core being constructed of a first material, a shell, said shell being positioned to surround said core, said shell being constructed of a second material, and magnetic particles, said magnetic particles being at least one of ferromagnetic particles and ferrimagnetic particles;   said magnetic particles being one of mainly arranged in said shell, almost exclusively arranged in said shell, and exclusively arranged in said shell;   a hybrid yarn, said hybrid yarn having a plurality of reinforcement fibers, a plurality of thermoplastic fibers; and   at least some of said plurality of thermoplastic fibers include at least one of proportionately ferromagnetic particles and ferrimagnetic particles.   
     
     
         40 . The fiber preform or semifinished textile product of  claim 39 , said fiber preform or semifinished textile product being produced by using TFP Technology. 
     
     
         41 . The fiber preform or semifinished textile product of  claim 39 , said fiber preform or semifinished textile product being produced by using Tow Placement Technology. 
     
     
         42 . A hybrid yarn comprising:
 a plurality of reinforcement fibers, a plurality of thermoplastic fibers, at least some of the plurality of thermoplastic fibers including at least one of proportionately ferromagnetic particles and ferrimagnetic particles; and   said yarn forming at least one of nonwoven fabric, non-crimp fabric, multiaxial multiply fabric, winding form, woven fabric, knitted fabric, and braided fabric.   
     
     
         43 . A method for producing a fiber preform or semifinished textile product comprising:
 providing a hybrid yarn, said yarn having a plurality of reinforcement fibers, a plurality of thermoplastic fibers, at least some of the plurality of thermoplastic fibers including at least one of proportionately ferromagnetic particles and ferrimagnetic particles; and   continually adding said hybrid yarn with simultaneous heating thereof in continuous passing through or passing by through a magnetic induction heating device or on the same and subsequent lay-up of said hybrid yarn in any path curve on a carrying layer and fixing of said hybrid yarn by allowing said yarn to rigidify.   
     
     
         44 . The method for producing a fiber preform or semifinished textile product of  claim 43  wherein said carrying layer is two-dimensional. 
     
     
         45 . The method for producing a fiber preform or semifinished textile product of  claim 43  wherein said fiber preforms are for endless fiber reinforced, fiber composite components. 
     
     
         46 . The method for producing a fiber preform or semifinished textile product of  claim 43  wherein said fiber preforms are for high performance fiber composite components. 
     
     
         47 . The method for producing a fiber preform or semifinished textile product of  claim 43  wherein said hybrid yarn is pressed during or after lay-up on said carrying layer. 
     
     
         48 . A fiber composite component comprising:
 at least one thermoplastic fiber, said thermoplastic fiber having a core, said core being constructed of a first material, a shell, said shell being positioned to surround said core, said shell being constructed of a second material, and magnetic particles, said magnetic particles being at least one of ferromagnetic particles and ferrimagnetic particles, said magnetic particles being one of mainly arranged in said shell, almost exclusively arranged in said shell, and exclusively arranged in said shell; and   a hybrid yarn, said hybrid yarn having a plurality of reinforcement fibers, a plurality of said thermoplastic fibers, and at least some of said plurality of thermoplastic fibers including at least one of proportionately ferromagnetic particles and ferrimagnetic particles.   
     
     
         49 . The fiber composite component of  claim 48  wherein the concentration of said particles is in a range of about 0.01 volume percent to about 20 volume percent. 
     
     
         50 . The fiber composite component of  claim 48  wherein the concentration of said particles is in a range of about 0.01 volume percent to about 2 volume percent. 
     
     
         51 . A fiber composite component comprising:
 at least one thermoplastic fiber, said thermoplastic fiber having a core, said core being constructed of a first material, a shell, said shell being positioned to surround said core, said shell being constructed of a second material, and magnetic particles, said magnetic particles being at least one of ferromagnetic particles and ferrimagnetic particles, said magnetic particles being one of mainly arranged in said shell, almost exclusively arranged in said shell, and exclusively arranged in said shell; and   a fiber preform or semifinished textile product, said fiber preform or semifinished textile product produced by providing a hybrid yarn, said yarn having a plurality of reinforcement fibers, a plurality of said thermoplastic fibers, at least some of said plurality of thermoplastic fibers including at least one of proportionately ferromagnetic particles and ferrimagnetic particles, and continually adding said hybrid yarn with simultaneous heating thereof in continuous passing through or passing by through a magnetic induction heating device or on the same and subsequent lay-up of said hybrid yarn in any path curve on a carrying layer and fixing of said hybrid yarn by allowing said yarn to rigidify.   
     
     
         52 . The fiber composite component of  claim 51  wherein the concentration of said particles is in a range of about 0.01 volume percent to about 20 volume percent. 
     
     
         53 . The fiber composite component of  claim 51  wherein the concentration of said particles is in a range of about 0.01 volume percent to about 2 volume percent. 
     
     
         54 . A fiber composite component comprising:
 a hybrid yarn, said hybrid yarn having a plurality of reinforcement fibers, a plurality of thermoplastic fibers, and at least some of said plurality of thermoplastic fibers including at least one of proportionately ferromagnetic particles and ferrimagnetic particles; and   a fiber preform or semifinished textile product, said fiber preform or semifinished textile product produced by providing said hybrid yarn and continually adding said hybrid yarn with simultaneous heating thereof in continuous passing through or passing by through a magnetic induction heating device or on the same and subsequent lay-up of said hybrid yarn in any path curve on a carrying layer and fixing of said hybrid yarn by allowing said yarn to rigidify.   
     
     
         55 . The fiber composite component of  claim 54  wherein the concentration of said particles is in a range of about 0.01 volume percent to about 20 volume percent. 
     
     
         56 . The fiber composite component of  claim 54  wherein the concentration of said particles is in a range of about 0.01 volume percent to about 2 volume percent. 
     
     
         57 . A fiber composite component comprising:
 at least one thermoplastic fiber, said thermoplastic fiber having a core, said core being constructed of a first material, a shell, said shell being positioned to surround said core, said shell being constructed of a second material; and magnetic particles, said magnetic particles being at least one of ferromagnetic particles and ferrimagnetic particles, said magnetic particles being one of mainly arranged in said shell, almost exclusively arranged in said shell, and exclusively arranged in said shell;   a hybrid yarn, said hybrid yarn having a plurality of reinforcement fibers, a plurality of said thermoplastic fibers, and at least some of said plurality of thermoplastic fibers including at least one of proportionately ferromagnetic particles and ferrimagnetic particles; and   a fiber preform or semifinished textile product, said fiber preform or semifinished textile product produced by providing said hybrid yarn and continually adding said hybrid yarn with simultaneous heating thereof in continuous passing through or passing by through a magnetic induction heating device or on the same and subsequent lay-up of said hybrid yarn in any path curve on a carrying layer and fixing of said hybrid yarn by allowing said yarn to rigidify.   
     
     
         58 . The fiber composite component of  claim 57  wherein the concentration of said particles is in a range of about 0.01 volume percent to about 20 volume percent. 
     
     
         59 . The fiber composite component of  claim 57  wherein the concentration of said particles is in a range of about 0.01 volume percent to about 2 volume percent. 
     
     
         60 . A method for producing fiber composite components comprising:
 providing the continuous addition of a hybrid yarn, said hybrid yarn having a plurality of reinforcement fibers, a plurality of thermoplastic fibers, and at least some of said plurality of thermoplastic fibers including at least one of proportionately ferromagnetic particles and proportionately ferrimagnetic particles;   simultaneous heating thereof in continuous passing through or passing by through a magnetic induction heating device or on the same and subsequent lay-up of said hybrid yarn in any path curve on a carrying layer and fixing of the hybrid yarn by allowing it to rigidify; and   thermoforming of the fiber preform produced for the production of a three-dimensionally formed fiber composite component.   
     
     
         61 . The method for producing fiber composite components of  claim 61  wherein said components are endless fiber reinforced, fiber composite components. 
     
     
         62 . The method for producing fiber composite components of  claim 61  wherein said components are high performance composite components. 
     
     
         63 . The method for producing fiber composite components of  claim 61  wherein said carrying layer is two-dimensional.