CN100469556C - Methods of forming a layered article - Google Patents
Methods of forming a layered article Download PDFInfo
- Publication number
- CN100469556C CN100469556C CN 200580003241 CN200580003241A CN100469556C CN 100469556 C CN100469556 C CN 100469556C CN 200580003241 CN200580003241 CN 200580003241 CN 200580003241 A CN200580003241 A CN 200580003241A CN 100469556 C CN100469556 C CN 100469556C
- Authority
- CN
- China
- Prior art keywords
- ground
- shaping
- thin layer
- sheet
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Images
Classifications
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
- Y02B10/00—Integration of renewable energy sources in buildings
- Y02B10/30—Wind power
Abstract
A method of forming a layered article, the method comprises thermoforming a substrate sheet to form a shaped substrate, wherein the shaped substrate is a fiber-reinforced plastic material having a void content sufficient to allow a vacuum to be applied through the shaped substrate; pulling a vacuum through the shaped substrate; and pulling a film layer onto a surface of the shaped substrate to form the layered article.
Description
The cross reference of related application
The application requires the priority of the U.S. Provisional Patent Application No.60/539188 of submission on January 26th, 2004, so this paper introduces it in full as a reference.
Background technology
The market economy that comprises the decoration composite construction of ground and decorative surface layer is often supported to use aathermoset resin system to be used for ground.Low raw material and processing cost usually are used as supports to select the factor of thermosets to quote.But, use thermosets can produce VOC (VOC) emission, and cause usually long circulation timei.
For example, a kind of common method that forms decorative element comprises two step process, wherein use the traditional hot manufacturing process to form thermoplastic surface's layer, behind this superficial layer, inject or spray the double-decker that thermosets and in-situ solidifying formation have enhancing bottom and thermoplastic surface's layer.Many thermosetting systems and method can be utilized and form the bottom that strengthens.These plastics (FRP), resin transfer moulding, vacuum that comprise that the glass fibre of for example eruption strengthens are injected and various enhancing froth in situ technology.
What need in this area is a kind of method of making layered article, compares with the present method of using thermal cure step, and this method can produce less VOC emission and have short circulation timei.
Summary of the invention
A kind of embodiment that forms the method for layered article comprises that hot forming ground sheet forms the shaping ground, and the ground that wherein is shaped is fibre-reinforced plastic material, and this material has the void content that is enough to allow to apply by the shaping ground vacuum; By shaping ground aspiration vacuum; To the surface of shaping ground, form layered article with the oriented film layer.
The another embodiment that forms the method for layered article comprises that heating ground sheet is to the temperature that is enough to allow ground sheet fiber flexible (lofting); Place the ground sheet against the forbay that film is auxiliary; Push the ground sheet and to mould, form the shaping ground; The heating thin layer; Place thin layer near the shaping ground; By shaping ground aspiration vacuum; With form layered article facing to shaping ground oriented film layer.
From the following detailed description, accompanying drawing and accessory claim, those skilled in the art can be familiar with and understand above-mentioned and further feature.
The accompanying drawing summary
With reference now to accompanying drawing,, they are exemplary embodiments, and wherein components identical is numbered in an identical manner.
Fig. 1 is that have will be by the cross-sectional side view of the matching tool of hot formed example ground.
Fig. 2 is that have will be by the cross-sectional side view of the auxiliary vacuum/pressurized equipment of the film of hot formed example ground.
Fig. 3 will be by the cross-sectional side view of the vacuum-thermoform system of hot formed thin layer for having on the shaping ground.
Fig. 4 is the cross-sectional view of exemplary plastic stratiform goods.
Describe in detail
Herein disclosed is its ground of manufacturing and have the method for the plastics layered article of open-celled structure.It should be noted that term used herein " perforate " has its original implication, and described the hole that is communicated with the adjacent bores fluid, thereby set up the fluid connection to the apparent surface from a surface.Term " hot forming " and its various languages of extending have their original implication, and are used for the general description heating becomes required form with matrix band method in this article.In DuBois and Pribble " Plastics Mold Engineering Handbook " the 5th edition (1995) 468-498 pages or leaves, describe thermo shaping method and instrument in detail.
For convenience, use term " layer " in this article, it can comprise having erose material and sheet and film.Also note that, term herein " first ", " second " etc. are not represented any order, quantity or importance, but being used to distinguish an element and another, the restriction of quantity do not represented in term herein " ", but there is at least one mentioned project in representative.In addition, all scopes disclosed herein be comprising property with capable of being combined (for example " the highest about 25 percetages by weight (wt%); wish that about 5wt% is to about 20wt%; and wish that more about 10wt% is to about 15wt% " scope comprise end points and whole medians of scope, for example " about 5wt% is to about 25wt%, and about 5wt% is about 15wt% extremely " etc.).
Method disclosed herein is particularly useful for comprising the manufacturing of the layered article that is arranged in thermoformable thin layer perforate, on the fibre-reinforced thermoformable ground.Thin layer can be used as the superficial layer of ground, and selected not only thermoformable but also compatible with ground.In one embodiment, thin layer is a decorative layer.In various embodiments, thin layer can comprise several layers, and for example thin layer can comprise superficial layer and compatibility layer.It should be noted that, in whole the disclosure, use term " thin layer " just to convenient, and can refer to that wherein thin layer is the embodiment of individual layer or the embodiment that it comprises several layers.In addition, the material of enumerating at thin layer can be the same material that uses in compatibility layer.If thin layer comprises extra play, for example compatibility layer will be appreciated that extra play is compatible with any other layer of any other layer that constitutes thin layer, ground and contiguous compatibility layer.
In addition, ground and thin layer can comprise identical or different plastic material compatible with each other." compatible " used herein is meant that layer can be incorporated into together, and can not interact unfriendly each other.Plastic material can comprise thermoplastic, thermosets and comprise combination at least a in the above-mentioned plastic material.Typical thermoplastic comprises polypropylene, Merlon (PC), polyester, PEI (PEI), poly (arylene ether) etc. and comprises combination at least a in the above-mentioned thermoplastic, for example PC/PET mixture.Suitable thermoplastic polyester for example comprises, poly-(dicarboxylic acids alkylene carbonate) as poly-(ethylene terephthalate) (PET), poly-(terephthalic acid (TPA)-1,4-Aden ester) (PBT), poly-(the inferior propyl ester of terephthalic acid (TPA)) (PTT), poly-(naphthoic acid ethyl) (PEN), poly-(naphthoic acid Aden ester) (PBN), poly-(terephthalic acid (TPA) cyclohexanedimethanoester ester), poly-(terephthalic acid (TPA) cyclohexanedimethanol-altogether-ethyl) (PETA) and poly-(1,4-cyclohexane dimethyl-1, the 4-cyclohexanedicarboxyester ester) (PCCD); Poly-(aromatic hydrocarbons diacid alkylene carbonate); With comprise combination at least a in the above-mentioned polyester.
In a kind of exemplary, ground and thin layer comprise Merlon separately.Can use the straight or branched aromatic polycarbonate.In one embodiment, can use the Merlon that comprises the one or more unit that obtain from following: 2, two (4-hydroxy phenyl) propane (" bisphenol-A ") of 2-, two (2-hydroxy phenyl) methane, 1, two (the 4-hydroxy phenyls)-3 of 1-, 3,5-trimethyl-cyclohexane, Fluorenone bis-phenol, 1, two (4-hydroxy phenyl) ethane, 2 of 1-, 6-dihydroxy naphthlene, two (3,5-diethyl-4-hydroxy phenyl) sulfone, 2, two (3, the 5-two bromo-4-hydroxy phenyls) propane, 4 of 2-, 4 '-dihydroxydiphenyl ether, the full bis-phenol of volution biindyl etc.
Typical thermosets comprises thermosetting resin such as epoxy resin, phenolic resins, alkyd resins, polyester, polyimides, polyurethane, mineral-filled siloxanes, BMI, cyanate, vinylite and benzocyclobutane olefine resin, and comprise above-mentioned at least a admixture, copolymer, mixture, product and compound.
The plastic material of ground has sufficient adhesive power and comes to provide sufficient structural integrity so that it can hot forming for ground.For example, ground can comprise that fiber and thermoplastic make ground can be placed in the thermoforming system and hot forming.In another exemplary, ground can comprise fiber, thermosets and reagent, and wherein reagent can keep the ground structure to be in required form (for example sheet) thereby make ground can be placed in the thermoforming system and hot forming.
According to the specific final use of goods, ground and/or thin layer can comprise one or more additives that are used to provide or strengthen visual effect.This vision additive includes but not limited to pigment and ornament materials such as sheet metal, dyestuff and luminophor.The object lesson of appropriate addn comprises metal oxide (as titanium dioxide and iron oxide); Metal hydroxides; Sheet metal (as aluminum slice); Chromate (as plumbous chromate); Sulfide; Sulfate; Carbonate; Carbon black; Silica; Talcum; Potter's clay; Phthalocyanine blue and green, organic red; Organic purplish red and other organic pigment and dyestuff etc., and at least a combination that comprises above-mentioned vision additive.In an exemplary, use at high temperature stable pigment, i.e. non-degradable substantially the or colouring agent that changes under about 350 ℃ temperature.
Also can there be the light resistance additive in thin layer and/or the ground, depends on the specific final use of goods equally.For example, thin layer and/or ground also can comprise light resistance compound, light resistance antioxidant and/or light resistance ozonant.The example of light resistance compound comprises two dodecyls-3,3 '-thiodipropionic acid ester, three (the 4-tert-butyl group-3-hydroxyl-2,6-dimethyl benzyl) isocyanuric acid ester, 1,3,5-trimethyl-2,4,6-three (3, the 5-di-tert-butyl-4-hydroxyl benzyl) benzene, N, N '-β, β '-naphthalene-4-phenylenediamine, 4,4 '-methylene-two (dibutyl two thiocarbamate esters), 2,2,4-trimethyl-1,2-quinhydrones etc.
Except above-mentioned additive or its substitute, can be in thin layer and/or ground the serviceability additive.Exemplary performance additive comprises impact modifying agent, UV absorbent, fire retardant, filler, stabilizing agent, ester exchange inhibitor, adhesion promotor such as bisphenol derivative, amino silane or derivatives thereof, releasing agent etc., and comprises combination at least a in the additive of these suggestions.The example of UV absorbers (UVA) comprises BTA, benzophenone, triazine, cyanoacrylate, DBR benzoxazinones etc. and hindered amine as light stabilizer (HALS) are as 2-(BTA-2-yl)-4-(1,1,3, the 3-tetramethyl butyl) phenol, 2-(BTA-2-yl)-4-methylphenol, 2-hydroxyl-4-octyloxy benzophenone, 2-hydroxyl-4-methoxy benzophenone, ethyl-2,2-diphenyl-1-cyanoacrylate, 2-(2 '-hydroxyl-4 '-octyloxy) two-4,6-(2 ', 4 '-3,5-dimethylphenyl) triazine, 2-ethyl-2 '-ethyoxyl oxalanide, two [2-hydroxy-5-methyl base-3-(BTA-2-yl) phenyl] methane etc.Also can use and comprise in the above-mentioned additive any one or multiple combination.
In addition, about ground, be enough to allow to apply the fibre-reinforced plastic material of vacuum for porosity after the hot forming by it.The porosity of noting ground can define according to the void content of ground.More particularly, hot formed ground (i.e. the shaping ground that forms by thermo shaping method) can have the void content more than or equal to about 5 percentage by volumes (vol%), especially about 10vol% is to the void content of about 50vol%, more particularly about 25vol% is to the void content of about 50vol%, and wherein percentage by volume is based on the cumulative volume of ground.For example, ground can be the fibre-reinforced plastic material of perforate.Perhaps, ground can be foraminate fibre-reinforced plastic material (for example, but punching press, boring, shaping, mold pressing or arrange that otherwise perforate passes through ground and/or shaping ground).Term " foraminate " has its original implication, and is used in reference to the ground in the hole that has physical layout therein in this article.Those skilled in the art it should be understood that open-celled structure can be interpreted as having " hole ", and for example, the hole that is communicated with the adjacent bores fluid is communicated with thereby set up fluid from a surface to the apparent surface.But, term " foraminate " whole open in just to convenient and be used to discuss those different systems of its hole and the pore network formation of fluid communication with each other.
Select the fiber that uses in the ground so that form fibre-reinforced plastics and the optional fibre-reinforced plastic material that forms perforate.Fiber type, size, quantity etc. can change with constituting the plastic material that uses in the ground.In a kind of exemplary, select fiber to give ground required voidage.Duplicate and required voidage fiber flexible (for example when being heated, on the z-direction, expanding) in order to obtain required mould.Exemplary fiber types includes but not limited to glass fibre (E glass (" electrical glass " for example, borosilicate glass for example), S-glass (" structural glass ", magnesia/aluminium oxide/silicate glass for example) etc.), mineral fibres, polymer fiber, natural fiber etc., and comprise combination at least a in the above-mentioned fiber.Randomly, fibre diameter (width) can be about 6 microns to about 25 microns.Randomly, fibre length can be about 2 millimeters (mm) to about 75mm.
The fiber reinforced plastic materials of ground comprises that the plastic material of q.s and fiber come to provide required structural intergrity and voidage for ground.For example, fibre-reinforced plastic bottom material can comprise the plastic material of about 25 percetages by weight (wt%) to about 75wt%, and especially about 35wt% more specifically can use the plastic material of about 40wt% to about 60wt% to about 65wt%.Can use about 25wt% to 75wt% with plastic material, especially about 35wt% is to about 65wt%, and more specifically about 40wt% is to the fiber of about 60wt%.Percetage by weight is based on the gross weight of fibre-reinforced plastic bottom material.
Suitable commercially available ground examples of material includes but not limited to
With
Glass Mat Thermoplastics (GMT), they can be from AZDEL, Inc., Shelby, NC obtains, and has various matrix, includes but not limited to polypropylene, Merlon (General Electric Company for example
), polyester (General ElectricCompany for example
), PEI (General Electric Company for example
), poly-inferior aryl oxide (polyphenylene oxide for example; General Electric Company's
Resin), polystyrene, polyamide and/or comprise above-mentioned at least a combination.
For example, can make ground (for example, as United States Patent (USP) 3938782 according to Wiggins Teape method; 3947315; 4166090; Discuss in 4257754 and 5215627).For example, for according to Wiggins Teape or similar approach manufacturing pad, metering fiber, thermoplastic and any additives also is distributed in the mixing channel that impeller is housed and forms mixture.By distribution header mixture is pumped in the flow box.Flow box is positioned at the top of the iron wire network segment of a class machine that is used for papermaking.Use vacuum to make the wire-mesh screen of mixture by moving of dispersion, produce the wet net of uniform fibers.If make wet Netcom super-dry device reduce moisture and use thermoplastic, melting heat plastic plastic material.The nonwoven scrim layer also can be adhered on the one or both sides of net, handles (being that ground provides structural intergrity with thermosets for example) easily to help ground.Make ground pass through idler roller and the required size of cutting (blocking) one-tenth then.
The optional tack coat that can be that is arranged between ground and the thin layer.The use of tack coat can provide the bonding of enhancing, by increasing the amount of resin at the interface, and or by improving the compatibility between thin layer and the substrate layer, especially when these layers comprise different resins.Tack coat comprises the selected material compatible with ground with thin layer.The object lesson that is used for the compatible material of tack coat comprises Merlon; Polyester such as PET, PBT, PTT, PEN, PBN, PETA and PCCD; PEI; Polyamide; Polyaromatic diacid alkylene carbonate; The resin that contains polyacrylonitrile is as, ABS, ASA or acrylonitrile-(vinyl-polypropylene diamines modification)-styrene (AES) for example; Diphenyl sulfide; Polymethyl methacrylate (PMMA); The copolyester carbonic ester; Poly-(dicarboxylic acids alkylene ester); Deng; Or comprise combination at least a in the above-mentioned polymer.In one embodiment, tack coat comprises the mixture of thin layer resin and substrate layer resin.
The mixture of Merlon and Merlon and polyester can be advantageously used in tack coat, especially combines with the thin layer that comprises aforesaid virtueization mylar.As everyone knows, Merlon has the loop structure unit as shown in following formula:
R wherein
1As top definition.Suitable polycarbonate resin comprises the straight chain aromatic polycarbonate resin, for example based on those and the side chain aromatic polycarbonate resin that comprise from the unit of bisphenol-A.
Polyester and comprise that the mixture of two or more polyester also can be advantageously used in tack coat, especially combines with the thin layer that comprises aforesaid virtueization mylar.For example, in mixture weight, a kind of suitable mixture that is used for tack coat comprise about 10wt% to PBT, the PET of about 50wt%, glycolized poly-(ethylene terephthalate), poly-(cyanoterephthalydene) (PCT), PCTA or PCTG and the about 50wt% virtue mylar of about 90wt% extremely, especially aforesaid resorcinol mylar and about 50wt% are to the resin that comprises resorcinol virtueization unit of about 90wt%.
Can be by method such as molding, extrude, apply, casting, vacuum moulding machine etc. separately make thermoformable thin layer and/or tack coat.Use adhesive adhesion and/or laminate layers then.At lamination is the application that is used for being arranged in subsequently the form of film on the ground that is shaped in advance, and tack coat can be used as the enhancement Layer that helps thin layer to handle, and it has relatively little inherent tensile strength.
Perhaps, make the thermoformable thin layer and the tack coat of lamination form by coinjection moulding, coextrusion, overmolding, coating etc.For example can come extrusion film layer and tack coat (with other optional layer) that it is contacted with each other when hot by the compressing tablet head that separates, then single by roller from the extruder that separates.In another embodiment, the polymer melt that constitutes the material of thin layer, optional tack coat and other optional layer can be brought to together and contacts with each other by coextrusion joint/feed head, then by list or manifold punch die.Structure joint/feed head makes the melt that forms separating layer be deposited on the melt of central core as adhesion coating.After the coextrusion, the multi-section multi-layer of the melt of generation can be shaped to required form in being connected the extrusion die in downstream: solid sheet or many wallboards.By calendering (solid sheet) or vacuum starching (many wallboards) cold fuse-element under controlled conditions in known manner, cut into chunks subsequently then.Can after starching or calendering, randomly provide annealing furnace to be used to reduce stress.
According to this method, ground is thermoformed into the shape that corresponds essentially to required end article shape.Usually, hot forming comprise continuously or simultaneously the heating and moulding material to mould, wherein material is initially the sheet form and is shaped as required form.In case obtain required shape, with regard to the cooling forming goods to it solidify or below the glass transition temperature.Usually, can use any void content of making to be enough to make the thermo shaping method of vacuum by its shaping ground that is sucked, for example void content is more than or equal to about 5vol%.For example, suitable thermo shaping method includes but not limited to mechanical molding's (for example matching tool shaping), film aux. pressure/vacuum forming, utilizes the film aux. pressure/vacuum forming of die-aid plug etc.
In the matching tool manufacturing process that ground is shaped, heating ground time enough makes ground reach softening temperature (it also can be called as forming temperature) so that ground can be become required shape by Physical Processing (promptly shaping) under enough temperature.Attention can be heated ground in every way, as in radiant heat shaping stove (it can comprise top and/or end heater).Then ground is placed on protruding forming tool and is recessed between the shape instrument.Be enough to ground is configured as under the pressure of required form by stop mechanism (stops) (being arranged in the periphery place of each instrument) make protruding be recessed into the shape instrument each other physics contact, keep void content simultaneously in above-mentioned scope.Suitable pressure will depend on concrete ground composition, and can need not just too much be tested and can easily be determined by those of ordinary skills.But, note avoiding using excessive pressure, because the part or all of hole of the closed ground of its possibility makes the ground porous insufficient to being lower than required void content.
With reference now to Fig. 1,, the cross-sectional view that provides matching tool to be shaped.Use anchor clamps 16 are fixed on the ground sheet 10 that heats with respect to protruding forming tool 12 and are recessed on the correct position of shape instrument 14.Note the protruding forming tool 12 of design and be recessed into shape instrument 14 " coupling " each other, promptly complementary.Protruding forming tool 12 and be recessed into shape instrument 14 and can randomly comprise a plurality of holes 18 and 20 respectively.Be arranged in protruding forming tool 12 and what be recessed into shape instrument 14 peripheries is respectively chocking construction (pad) 22 and 24, they are used to determine the thickness of shaping ground.Chocking construction 22 and 24 is positioned at the shaped region outside.Protruding instrument 12 and recessed instrument 14 are made of the material compatible with the ground material.For example, instrument can by but be not limited to following material and constitute: aluminium, steel, epoxy resin, silicon rubber, molding are with potting resin etc.
In forming process, the heating ground is to being enough to allow hot forming and being enough to allow the flexible temperature of fiber in the ground ideally.For example, about 450 ℉ (about 232 ℃) are to about 700 ℉ (about 371 ℃), and more particularly about 550 ℉ (about 288 ℃) are suitable for the Merlon ground sheet of hot forming glass fibre enhancing to the temperature of about 650 ℉ (about 343 ℃).Then by between protruding instrument 12 and recessed instrument 14, setting up the ground that relative motion makes that chocking construction 22 contact chocking constructions 24 are shaped and heat.Make protruding instrument 12 and recessed instrument 14 with therebetween ground sheet 10 to causing ground sheet 10 to meet the shape of protruding and recessed instrument 12,14.Can cool off ground then and form the shaping ground.Use about 1 atmospheric pressure (about 101kPa) to about 10 atmospheric pressure (about 1013kPa), more particularly about 1 atmospheric pressure (about 101kPa) to the pressure of about 5 atmospheric pressure (about 507kPa) to be shaped
Ground.
In film assisted vacuum/pressure forming method, place the ground of heating facing to forbay.Vacuum and pressure are applied simultaneously on the ground.More particularly, by the forming tool aspiration vacuum, normal pressure is applied on the film side relative with the side of the most close forming tool.The direction of vacuum and pressure is illustrated to point out in Fig. 2 with arrow.The vacuum that applies by mould makes sheet be stretched in the mould/go up (hereinafter for last).Suitable pressure (positive and negative) will depend on concrete ground, and can need not just too much be tested and can easily be determined by those of ordinary skills.In addition, as mentioned above, avoid excess pressure, because its possibility closing section or whole hole make the ground porous insufficient.
Fig. 2 has schematically illustrated the auxiliary vacuum/pressurized thermo shaping method of film.The ground 26 of heating is arranged between forbay 28 and the forming tool 30.Although forming tool 30 can be protruding forming tool or is recessed into the shape instrument, forming tool 30 is illustrated as protruding forming tool.Forming tool 30 comprises that hole 32 makes and can apply vacuum by forming tool 30.Can use anchor clamps 34 that the ground sheet is fixed on correct position with respect to forbay 28 and forming tool 30.Film 36, more particularly, impermeable membrane is crossed the opening of forbay 28 by elongation.As mentioned above, by passing the vacuum that forming tool 30 is sucked the first surface 26A of ground 26 is contacted with forming tool 30 physics, and second surface 26B is contacted with film 36 physics.36B applies pressure on the film 36 from the film side.Because ground is the aforesaid fiber-reinforced thermoplastic that has more than or equal to the perforate of the void content of about 5vol%, therefore directly pass through ground 26 aspiration vacuum.Thereby, use film 36 to promote grounds (promptly when from the malleation of forbay 28 during towards instrument 30 promotion films 36, vacuum is sucked by ground 26, and towards instrument 30 stretched film 36 and ground 26) to forming tool 30.In other words, vacuum can not be sucked by film 36.On the contrary, when pressure on being applied to film 36 promoted film 36 towards forming tool 30, vacuum was towards forming tool 30 stretched film 36.In case ground is on forming tool 30, it just is cooled and forms the shaping ground.For example, if
Be ground, then can to film 36 apply about 1 atmospheric pressure (about 101kPa) to the pressure of about 5 atmospheric pressure (about 507kPa) to promote grounds 26 towards forming tool 30, pass through forming tool 30 aspiration vacuum simultaneously.More specifically, can apply the pressure of about 1 atmospheric pressure (about 101kPa) to film 36 to about 3 atmospheric pressure (about 304kPa).
Provide above-mentioned thermo shaping method only to be used for illustrative purpose.It should be understood that and can ground is shaped by any thermo shaping method, the molded ground that wherein obtains has the void content that can apply vacuum by ground.
With after producing the shaping ground, can randomly repair the extremely roughly net shape of required goods of shaping ground at the hot forming ground.Finishing can be to be shaped and arrange on the ground and carry out before or after the thin layer.Method for trimming can comprise for example laser reconditioning, jet finishing, the finishing of mould preparation trimmer etc., and comprises combination at least a in the said method.
Thin layer comprises that to the deposition on the shaping ground use shaping ground is stretched to thin layer on the shaping ground as forming tool.Therefore, in case be formed, the shaping ground just can be retained in to be accepted thin layer or is moved on the different forming tools on the forming tool.Although the shaping ground can not use with forming tool, for structural intergrity wishes to use forming tool.Applying thin layer in the process of shaping ground, by top be that the described similar fashion of ground heats thin layer, and use anchor clamps for example that it is fixed on correct position with respect to fixator and ground.To ground, form layered article with the oriented film layer by shaping ground aspiration vacuum then.In various embodiments, can introduce tack coat between ground and the thin layer to improve the bonding force between ground and the thin layer.When using tack coat, gone forward to the shaping ground by hot forming at thin layer, tack coat is placed on the thin layer, between shaping ground and thin layer, thereby when thin layer was stretched on the shaping ground, tack coat also was stretched on (with extending to) shaping ground.This tack coat can help bonding shaping ground and thin layer to arrive together.
With reference now to Fig. 3,, illustrates the cross-sectional side view of application of vacuum building mortion with ground.Shaping ground 38 is placed on the protruding forming tool 40 that comprises a plurality of holes 42.The thin layer 44 of heating plate form, and be fixed on the appropriate location with respect to shaping ground 38 and protruding forming tool 40 by anchor clamps 46.By forming tool 40 aspiration vacuum, shown in arrow among the figure.Because shaping ground 38 has enough porositys vacuum is sucked by it, so superficial layer 44 is stretched on the shaping ground 38 and forms layered article.Notice in various embodiments, can for example repair layered article on the protruding forming tool 40 by for example above-mentioned those method for trimming of any method for trimming.
Can be shown in Fig. 4 by the exemplary shaping multi-layer product 110 that this method obtains, and comprise thin layer 112 and ground 114.Thin layer 112 can be used as the superficial layer of ground, selects its not only thermoformable but also compatible with ground.In one embodiment, can utilize the outer surface of surface design structure thin layer 112, and/or outer surface can comprise the additive that optical effect can be provided.
Still as shown in Figure 4, optional first compatibility layer 116 that can comprise additive that optical effect can be provided can be disposed between thin layer 112 and the ground 114.When using the first optional compatibility layer 116 that optical effect is provided, thin layer 112 is transparent.The combination of the thin layer 112 and first compatibility layer 116 often is called as decorative layer, and is shown 118 in Fig. 4.
Also can between ground 114 and first compatibility layer of choosing wantonly 116 or thin layer 112, arrange tack coat 120.Tack coat 120 can be used for increasing bonding between the layer.When not having tack coat, the first optional compatibility layer can be used for increasing bonding between thin layer 112 and the ground 114.
Can on a side of the ground 114 relative, arrange optional balance layer 122 with thin layer 112.The purpose of balance layer 122 is layers that coupling thin layer 112 thermal coefficient of expansions are provided on a side of the ground 114 relative with thin layer 112.Can between ground 114 and balance layer 122, arrange second tack coat 124.In addition, can between balance layer 122 and tack coat 124 or ground 144, arrange the second compatibility layer (not shown).It should be understood that the goods 110 that any required form can be provided, this is by the final use defined of goods.
The structural articles that uses material disclosed herein and method to form can comprise any application that the laminated plastics goods may be favourable.For example, goods include but not limited to be used for the outside and the inner member of aircraft, automobile (for example car, truck, motorcycle etc.).For example, various elements include but not limited to panel, dumb card, rocker panel, vertical panel, horizontal panel, dashboard, head line, door etc.
Advantageously, compare with the method for using thermosets, method disclosed herein has been simplified not the decorating structure part of japanning and the production of panel.In various embodiments, the production of these parts can be in single forming station to carry out than the present possible higher efficient of efficient.Use hot formed method to need independent non-hot forming step that ground or bottom are arranged on the layer (for example formed film layer) that is shaped, for example by spraying, injection etc.But,, also can use hot forming to apply thin layer by the vacuum of using void content to be enough to make to pass the shaping ground the to be sucked this ground of other layer to the ground that stretch.Because the shaping ground can be formed on protruding or the die, therefore layer (for example thin layer) subsequently can be the decorative layer that is applied on the shaping ground outer surface.
This method has reduced the device type that is used to produce these laminar products, and can reduce formation time and simplify the layered article manufacturing process.In addition, when this thermo shaping method does not use thermosets, compare, significantly reduced the VOC emission, if indelible words with other method of using thermosets.The lower pressure that uses in method disclosed herein also allows low relatively processing cost.At last, the porosity characteristic of ground structure helps to reduce the thermoelastic stress that occurs in the superficial layer attaching process below.
Although described the present invention according to exemplary, those skilled in the art can recognize, only otherwise depart from the scope of the present invention, can make various variations, and replace its key element with equivalent.In addition, only otherwise break away from base region of the present invention, can make multiple improvement and make specific situation or material be fit to instruction of the present invention.Therefore, the present invention does not plan to be limited to the disclosed particular of best mode as consideration into enforcement the present invention, but the present invention will comprise all embodiments that drop in the accessory claim scope.
Claims (19)
1. method that forms layered article, this method comprises:
Hot forming ground sheet forms the shaping ground, should the shaping ground be fibre-reinforced plastic material wherein, this material has the void content that is enough to allow to apply by the shaping ground vacuum, and wherein said void content is more than or equal to 5 volume %, in the cumulative volume of described shaping ground;
By shaping ground aspiration vacuum; With
The oriented film layer to the surface of shaping ground to form layered article.
2. the process of claim 1 wherein that thin layer also comprises compatibility layer.
3. the process of claim 1 wherein that void content is 10vol% to 50vol%.
4. the method for claim 3, wherein void content is 25vol% to 50vol%.
5. the process of claim 1 wherein that fiber has 6 microns to 25 microns fibre diameter and 2 millimeters to 75 millimeters fibre length.
6. the process of claim 1 wherein that the shaping ground is porose.
7. the process of claim 1 wherein that the shaping ground is the fibre-reinforced plastic material of perforate.
8. the process of claim 1 wherein that the ground sheet comprises:
The plastic material of 25wt% to 75wt%;
The fiber of 25wt% to 75wt%; With
Wherein wt percentage is based on the gross weight of ground sheet.
9. the method for claim 8, wherein the ground sheet comprises:
The plastic material of 35wt% to 65wt%; With
The fiber of 35wt% to 65wt%.
10. the method for claim 8, wherein plastic material be selected from polyester, PEI, polyphenylene ether, polystyrene, polyamide and comprise above-mentioned at least a combination.
11. the method for claim 8, wherein plastic material is a Merlon.
12. the process of claim 1 wherein and use the film assisted vacuum pressure forming method hot forming ground sheet that utilizes die-aid plug.
13. the method for claim 1 also is included between shaping ground and the thin layer and arranges tack coat.
14. the process of claim 1 wherein that hot forming ground sheet comprises that also the heating ground is to the temperature that is enough to allow fiber flexible.
15. the method for claim 14, wherein temperature is 232 ℃ to 371 ℃.
16. the process of claim 1 wherein that the ground sheet also comprises is arranged in the lip-deep nonwoven scrim of ground sheet.
17. a method that forms layered article, this method comprises:
Heating ground sheet is to the temperature that is enough to allow ground sheet fiber flexible;
Place the ground sheet facing to the forbay that film is auxiliary;
Push the ground sheet and form the shaping ground to mould, wherein said shaping ground is the fibre-reinforced plastic material of void content more than or equal to 5 volume %, and described void content is in the cumulative volume of described shaping ground;
The heating thin layer;
Place thin layer near the shaping ground;
By shaping ground aspiration vacuum; With
Form layered article facing to shaping ground oriented film layer.
18. the method for claim 17, wherein void content is 10vol% to 50vol%.
19. the method for claim 17 also is included between shaping ground and the thin layer and arranges tack coat.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US53918804P | 2004-01-26 | 2004-01-26 | |
| US60/539,188 | 2004-01-26 | ||
| US10/805,760 | 2004-03-22 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN1914023A CN1914023A (en) | 2007-02-14 |
| CN100469556C true CN100469556C (en) | 2009-03-18 |
Family
ID=37722544
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN200580003140.3A Expired - Fee Related CN1914024B (en) | 2004-01-26 | 2005-01-13 | Structurally reinforced resinous article and method of making |
| CN 200580003241 Expired - Fee Related CN100469556C (en) | 2004-01-26 | 2005-01-14 | Methods of forming a layered article |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN200580003140.3A Expired - Fee Related CN1914024B (en) | 2004-01-26 | 2005-01-13 | Structurally reinforced resinous article and method of making |
Country Status (1)
| Country | Link |
|---|---|
| CN (2) | CN1914024B (en) |
Families Citing this family (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102225703A (en) * | 2011-04-12 | 2011-10-26 | 江西洪都航空工业集团有限责任公司 | Manufacturing method of integral glass fiber reinforced plastic unmanned aerial vehicle wing |
| CN102958300B (en) * | 2011-08-29 | 2017-02-08 | 深圳富泰宏精密工业有限公司 | Resin and fibre compound body and manufacturing method thereof |
| US9738054B2 (en) * | 2014-10-21 | 2017-08-22 | The Boeing Company | Tailored coefficient of thermal expansion of composite laminates using fiber steering |
| CN106340722B (en) * | 2015-07-10 | 2021-01-22 | 深圳光启尖端技术有限责任公司 | Antenna shell group and manufacturing method thereof |
| US10611097B2 (en) * | 2016-05-24 | 2020-04-07 | General Electric Company | Methods and systems including pressurized housings for forming materials |
| EP3473399B1 (en) * | 2016-06-17 | 2021-06-30 | Aisin Seiki Kabushiki Kaisha | Production method and production device for thermoplastic resin composite material |
| WO2019189582A1 (en) * | 2018-03-30 | 2019-10-03 | 東レ株式会社 | Method for manufacturing molded article |
| CN109305352B (en) * | 2018-11-29 | 2021-04-30 | 长沙神弓信息科技有限公司 | Unmanned aerial vehicle and manufacturing method of body shell of unmanned aerial vehicle |
| CN110435164A (en) * | 2019-07-19 | 2019-11-12 | 中国工程物理研究院化工材料研究所 | A method of it reducing fragile material open-celled structure stress and concentrates |
| CN114506010B (en) * | 2022-02-24 | 2023-08-22 | 江苏锐创阀业有限公司 | Compression molding process of high-strength heat exchanger tube steel lining plate |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2840246B1 (en) * | 2002-05-28 | 2005-05-20 | Chomarat Composites | NEW PROCESS FOR FORMING AND STRENGTHENING THERMOPLASTIC PIECES |
-
2005
- 2005-01-13 CN CN200580003140.3A patent/CN1914024B/en not_active Expired - Fee Related
- 2005-01-14 CN CN 200580003241 patent/CN100469556C/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| CN1914023A (en) | 2007-02-14 |
| CN1914024A (en) | 2007-02-14 |
| CN1914024B (en) | 2011-06-29 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN100469556C (en) | Methods of forming a layered article | |
| KR101148420B1 (en) | Methods of forming a layered article | |
| AU2005228938B2 (en) | Reinforced resinous article and method of making the reinforced resinous article | |
| MX2007000819A (en) | Method for making multilayer film, sheet and articles therefrom. | |
| CN1910043A (en) | Weatherable multilayer article assemblies and method for their preparation | |
| US7060217B2 (en) | Composite articles comprising resorcinol arylate polyester and method for making thereof | |
| US20100276075A1 (en) | Bonding and layering of sheets of raw material | |
| EP1055512B1 (en) | Molded article and process for preparing same | |
| KR100923441B1 (en) | Real material film, goods using the same and methods for those | |
| CN100548635C (en) | The surface decoration technique of composite | |
| CN100584878C (en) | Gel coated reinforced composite | |
| KR102187819B1 (en) | Composite materials having natural fibre for interior parts of vehicle, and method for manufacturing the same | |
| EP1507646B1 (en) | A method of producing a three-dimensional article having a sandwich structure | |
| US20020187702A1 (en) | Composite thermoplastic-thermoset resin material | |
| KR20210006491A (en) | real wood interior material and manufacturing method thereof | |
| KR20140069870A (en) | Garnish for interial parts of automobile and manufacturing method of the same | |
| JPH0745129B2 (en) | Resin panel manufacturing method | |
| JPH04179521A (en) | Manufacture of composite molded form | |
| KR20090025925A (en) | Sunshade board and manufacturing method | |
| JPH09156047A (en) | Paintless film |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| C06 | Publication | ||
| PB01 | Publication | ||
| C10 | Entry into substantive examination | ||
| SE01 | Entry into force of request for substantive examination | ||
| REG | Reference to a national code |
Ref country code: HK Ref legal event code: DE Ref document number: 1100875 Country of ref document: HK |
|
| C14 | Grant of patent or utility model | ||
| GR01 | Patent grant | ||
| REG | Reference to a national code |
Ref country code: HK Ref legal event code: GR Ref document number: 1100875 Country of ref document: HK |
|
| C56 | Change in the name or address of the patentee | ||
| CP01 | Change in the name or title of a patent holder |
Address after: Bergen Op Zoom Holland Patentee after: Sabic Innovative Plastics IP Address before: Bergen Op Zoom Holland Patentee before: Sabic Innovative Plastics Ip |
|
| CF01 | Termination of patent right due to non-payment of annual fee |
Granted publication date: 20090318 Termination date: 20210114 |
|
| CF01 | Termination of patent right due to non-payment of annual fee |