CN101031420A - Recyclable composite plastic and related manufacturing methods - Google Patents
Recyclable composite plastic and related manufacturing methods Download PDFInfo
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- CN101031420A CN101031420A CN 200580030198 CN200580030198A CN101031420A CN 101031420 A CN101031420 A CN 101031420A CN 200580030198 CN200580030198 CN 200580030198 CN 200580030198 A CN200580030198 A CN 200580030198A CN 101031420 A CN101031420 A CN 101031420A
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Abstract
A method of producing a panel having at least one feature comprising a discontinuation in curvature of surface in the surface, the method comprising the steps of: providing a first reinforced layer of long and/or continuous parallel fibre reinforced thermoplastic of a first polymer (102a, 104a); providing a core layer of thermoplastic with at least roughly 70% by volume of a second polymer which is compatible with the first polymer (106); providing a second reinforced layer of long or continuous parallel fibre reinforced thermoplastic of the first polymer (102b, 104b); stacking the layers such that the reinforced layers are separated by the core layer; introducing the stack into a panel mould and heating the mould to at least the melting point of the predetermined polymer to consolidate the layers and form the panel.
Description
The field of the invention relates to composite plastic and relative manufacturing process thereof.
Plastics as a kind of multipurpose and easily material be used for multiple product, and in very big range of application, replace materials such as metal or timber.The convenience of plastics can present complicated shape because of its ductility, and possesses durability than employed material of past.In addition, the numerous plastics of existing classification have different character, as fusing point, hardness, density etc., can find a kind of suitable plastic for the application of broad range thus.
Also commendable is, and but multiple plastics are arranged is recycling (this is applied to so-called thermoplastic, compares with thermosetting plastics, and it can be melted once more).Under the situation that environmental problem becomes more and more important for user and important legislation theme, this is useful especially.But present many countries all encourage the product in industrial use or manufacturing recycling.
Yet existing plastics can not always reappear the character of other material.The imagination example is the bonnet of automobile; require firm (if bumping), flexible (in collision, protecting the pedestrian) with passenger in the protection car; low thermal coefficient of expansion (will consider cover cap by engine heating be to be under the sun only, it is very important that this position does not change shape and size) also will be arranged.And then also have manufacturing advantage-this position must coat with lacquer and be coated with, and with rational cost manufacturing.Obtain required form and required design details aspect, for example be used for the embedding position of motor corporation's badge, preferably light-dutyer (it is more cheap or performance is better that light-dutyer automobile is compared operation with the heavy automobile of same model) and easy molding.
In the past, steel, aluminium or thermosetting plastics have been used to make automobile engine cover, ceiling and other similar portions.Yet the instrument preparation cost of this method makes steel and aluminium undesirable, also is not suitable for small quantities of production operation.Thermosetting plastics normally can not recycling.
The fibre strengthening plate is used to provide the plastic material that has improved mechanical performance to be known by the public.The manufacturing of this material is that document is known, for example US5194462 has described a kind of method of making matt glass heat plastic material, wherein the fiber of Qiang Huaing is arranged with the continuous gradient layer structure, this wherein the density of fiber from the high-density layer to the low-density layer, change continuously.This technology is commonly referred to " pellicular cascade " (film stack) technology.Other the method for making random (random) fibre substrate in thermoplastic comprises that " ICI heat pipe technology ", " Flexline ", " Bay Mills/Spiflex ", " Radlite " and powder inject.
According to a first aspect of the invention, provide a kind of method of producing panel, described panel has discontinuous this feature of surface curvature at least from the teeth outwards, and this method comprises the steps:
Provide the first polymeric thermoplastic plastics long and/or parallel fibers reinforcement continuously as first strengthening layer;
The thermoplastic that second polymer is provided is as sandwich layer, and this second polymer and first polymer are compatible;
Provide the first polymeric thermoplastic plastics long or parallel fibers reinforcement continuously as second strengthening layer;
Folded layer by layer strengthening layer is separated by sandwich layer each;
With this lamination lead-in surface board mold and heat this mould to the fusing point of predetermined at least polymer to solidify each layer and to form panel.
Those skilled in the art can be understood that, the parallel fibers on the aspect can be facing one direction or more than a direction, for example in the braided fiber strengthening material.In addition, be understandable that top used " compatible " refers to each plastic layer congruent melting.Compatible polymer has identical polymer substrate probably.Be understandable that for thermosetting plastics sandwich and strengthening layer can not melt in the same manner, so thermoset plastic material is unsuitable for this method.
In addition, the discontinuity of surface curvature can, for example comprise round shape at the edge of panel, maybe can comprise a depression.In one embodiment, panel is the panel of vehicle body, and depression can comprise badge or a special design feature, for example fin, ventilating opening, burr, ripple or the like that a recess is used for motor corporation.
With two layers of reinforced material is useful with hardness and the intensity that increases panel separately, makes that panel can instead of steel backplate (latter is very expensive) and thermosetting plastics panel (latter be can not recycling).This material also demonstrates flexibility, and can improve pedestrian's safety.Reinforcing fiber can suppress the thermal expansion of panel, so it can be used for being in the part under the high thermic load, for example is subjected to roof of the vehicle or bonnet that solar heat shines.In addition, thus the step of heating mould can make easily japanning of smooth surface.Core provides one deck to be rich in polymeric layer, the permeable strengthening layer of the polymer of this layer and especially be seeped into the sharp-pointed angle of mould, thus fill up the space of staying between strengthening layer and these angles.It will be understood by those skilled in the art that the panel of formation can follow the shape of mould better.In addition, heating mould makes and can adopt lower pressure in moulding technology, this means and can implement accurate " in the mould " (in-mould) technology, for example lays circuit board.
The claimed method of the application is combined first strengthening layer, sandwich layer and second strengthening layer as can be seen; wherein first strengthening layer is the first polymeric thermoplastic plastics of length or continuous parallel fibers reinforcement, and second strengthening layer is the long or continuous parallel fiber strengthened first polymeric thermoplastic plastics.Each layer all can be by commercially available product composition, but the composite construction of this method manufacturing has described advantageous property herein, and this is that any initiation material institute is inaccessiable.
Sandwich layer can be provided by any suitable material, example comprises random glass reinforced thermoplastic as " Azdel ", and by U.S. GE Azdel, Southfield MI 48076 produces, or from Switzerland Quadrant Composites of Lenzburg, like product.
First and second strengthening layers can be provided by continuous unidirectional fibre reinforced material.This examples of material has the Gurit Suprem from Switzerland, the material of CH-8247Flurlingen commodity by name " Plytron ", or from the like product of Japanese Mitsui.Also can utilize the like product in various sources.Another selectable embodiment is that the product for powder coated can utilize continuous fiber, but thinks that the character of the composite construction that obtains is not good.
Preferably sandwich layer has second polymer (that is to say that sandwich layer has other material near about 30%, it typically is strengthening material) at least about 70% stereometer.Provide the sandwich layer of second polymer with common 70% stereometer to be equivalent to provide a kind of like this structure, this structure has material with strengthening layer suitable approximately core material on volume.
Provide the second kind of polymer that has by volume more than surfacing summation 50% to be considered to useful because its sandwich layer that provides usually the thickness summation with two layers of reinforced material is suitable approximately on thickness.Can keep hardness and dimensional stability like this, improve processing characteristics simultaneously and reduce cost.
(polymer that depends on use) in some embodiments, this method comprise that further as-molded panel is carried out flame treatment, corona discharge or plasma gun to be handled.What know to those skilled in the art is can improve the adhesion that surface tension is improved paint thereby handle polymer by these modes.
Those skilled in the art can be understood that, " long fibre " (long-fibre) reinforced themoplastic plastics is to be impregnated with (impregnated) with fiber, and fiber wherein is common glass, carbon, synthetic or natural material, keeps its shape with this under different environmental conditions.Skilled person will appreciate that the implication of term " length " in the art be the length that has of fiber for about 1mm between about 10mm, and the length that continuous fiber has is for arriving the length of the applied product of fiber above any length of about 10mm.Short fiber is interpreted as that length is less than about 1mm.In an especially preferred embodiment, fiber be continuous and therefore can be used for any length at 10mm near the scope between the rough length of manufacturing panel.
First polymer can be identical or essentially identical polymer with second polymer.This is useful, because such panel is meltable and can recycle, and panel be in conjunction with having unpredictable character more than a kind of polymer, and it utilizes and may be restricted or be suppressed.
Molding can carry out in vacuum solidification mould, diel or any other suitable mould.These are convenient moulds used in the art.
In preferred embodiments, finished surface (tooling surface) (i.e. the surface that contacts with panel) heats.This compares with the heating entire die can conserve energy.
And then, in a preferred embodiment, at least the finished surface that will be used for a side of panel that will japanning is carried out molding is heated.This is useful, because the step of heating makes plastics reach fusing point and forms the surface of smooth and easy japanning.
This method can further comprise cooling die.This can be so that panel cooling and faster than the process that allows mould cool off voluntarily.Mould can be by utilizing the cooling of cooling fluid or alternate manner.In some embodiments, particularly have only in the heated scheme of finished surface, have only finished surface to be cooled.This can reduce the requirement of cooling fluid.
This method can comprise provides sandwich layer to make it account for about 50% of plate thickness.This is suitable, because it makes strengthening layer by suitable width separately (as rule, they are got more and open, and the hardness of panel is high more).Yet in an alternative embodiment, sandwich layer can comprise arbitrarily following thickness: 25%, 40%, 60%, 80% or between numerical value.
In some embodiments, this method can comprise provides more than two layers of reinforced material.In a possible preferred embodiment, each side at sandwich layer all has two layers of reinforced material, wherein the fiber of outermost layers incorporate is at first direction, and the fiber of internal layer strengthening layer combination is arranged sandwich layer in the second direction perpendicular to first direction between the internal layer strengthening layer.This is useful, because fiber can limit thermal expansion at both direction.
In a preferred embodiment, one or more layers strengthening layer of sandwich layer one side can be arranged as basically and become the minute surface symmetry with one or more layers strengthening layer of sandwich layer opposite side.The quantity that this means the layer of sandwich layer both sides is balance, and the direction of fiber also is the minute surface symmetry, for example in one 5 layers structure, outermost layer can comprise longitudinally fiber and the nexine strengthening layer can comprise horizontal fiber (seeing Fig. 1 of the example of arranging as " minute surface symmetry ").This set is useful, because can avoid distortion.Should be noted that further processing for example goes up enamelled coating or braiding (fabric) layer---can not break the balance of panel.
In another optional embodiment, method of the present invention comprises to one or more layers strengthening layer provides the fiber of laying along two rough mutually perpendicular directions.For example can be referred to as 0 ° of 90 ° of matrix by term usually in the aspect of first and second strengthening layers and lay, center/core becomes the minute surface symmetry relatively.
This one or more layers strengthening layer can be further or alternatively, comprises the fiber of laying with diagonal, and this is called " quasi-isotropic " (Quasi isotropic) in the art and is provided with.In this embodiment, this method before can being included in and being attached to fiber in the layer knits together it.This only can pass through, and two layers of reinforced material limits thermal expansions in a plurality of directions.
In addition, or in an optional embodiment, this method can comprise provides one deck to obtain multilayer strengthened layer, thereon not being that 90 ° angle is laid fiber mutually.Fiber is oriented to about 37 ° mutually in a useful especially embodiment.In the situation of polypropylene matrix, this is considered to useful especially, because it gives resulting plastic material and the general suitable hot expansion property of steel.The thermal property of synthetic plastics material can change other angle into by the mutual orientation with fiber and be complementary with other material.
This method can comprise to sandwich layer provides reinforcing fiber.Suitable fiber can be randomly-oriented fiber.This can strengthen the intensity of panel.Optionally, core can be a material natural or that do not strengthen.This is useful, because it can improve the ductility of panel.
Core can be made up of recycled materials, the plastic components that for example pulverizes.In one embodiment, bumper (bumper) can be recycled.It will be appreciated by those skilled in the art that bumper material does not comprise fibre strengthening usually, but " filler " arranged, generally is synthetic rubber, thereby improves impact property and paint adherence.But bumper is japanning also.The bumper that pulverizes can be thought the filling level (filled grade) of paint particles, and paint particles is also served as filler in ground material.Thinking in the past that such recycled materials can not be used to make requires firm panel.This is because impurity causes discontinuity in the structure, the latter that the tendency of fracture is subsequently arranged in those positions as the paint speckle.Yet in the solution of the present invention, intensity is provided by strengthening layer, and recycled materials can directly use and need not peel the paint part earlier off or remove other impurity.
Sandwich layer also can be made up of the abrasive material again (as from fiber factory) of industry or the terminal thing of recirculation (as packing).
The inventive method comprises the production that panel is used for the vehicles.Panel can be used as bonnet, ceiling or the Sorte Nula as automobile.Optionally, it also can be used for the door of aircraft or the panel of fuselage part.
According to a second aspect of the invention, a kind of panel that is formed by laminated composite materials is provided, it comprises: comprise the thermoplastic sandwich layer of at least 70% predetermined polymer by volume, cover layers with the predetermined polymeric thermoplastic plastics that comprise long and/or continuous fiber reinforcement, wherein long and/or continuous fiber is parallel with tectal surface orientation, internal layer covers each surface at least in part by cover layer, and wherein each layer solidifies in heated mold.
Preferably, the arrangement of these materials makes that the polymer of sandwich layer will be pulled to tectal surface when cover layer is heated.
The smooth surface that easy japanning is provided is useful.
Preferably, lamination comprises at least three layers, and two outside layers comprises the general polymerization thing thermoplastic that continuous fiber is strengthened, and one deck internal layer comprises the general polymerization thing thermoplastic of not strengthening or random fiber is strengthened at least.
Each layer can solidify in the vacuum solidification mould or solidify through punching press.This is the facilitated method that this area is used to make panel.
According to a third aspect of the invention we, a kind of composite plastic is provided, it comprises: one deck is scheduled to the internal layer of polymeric thermoplastic plastics at least, and the cover layer of the predetermined polymeric thermoplastic plastics of two-layer at least length or continuous fiber reinforcement, wherein long and/or continuous fiber is substantially parallel with tectal surface orientation, and the internal layer cap rock that normally is covered covers each surface.
Such composite plastic is useful, because cover layer makes this composite sample can keep its shape under different environmental conditions, internal layer can provide higher ductility.
Tectal in an especially preferred embodiment fiber is continuous.
According to a forth aspect of the invention, provide a kind of method of on the fiber reinforced plastics panel, painting, comprise coating thixotropic (thixotropic) ground floor priming paint, make ground floor form rigidity coating (coating), be coated with second layer paint vehicle again.This is useful, because the composite laminate plastic front board can comprise that with fibre-reinforced skin fiber can be glass, carbon, natural or synthetic fibers.Such panel is in the experience variations in temperature, as in the sun, can produce varied in thickness because of thermal expansion and thermal contraction.In expansion, enamelled coating may arch up, and may remain on that position after contraction.This may cause through after a while " trace mark " (witness marks), especially fiber, is left in the finish (paint finish).
In some embodiments, plastics can comprise composite plastic.In such embodiments, compoundly comprise at least three layers, two outside layers comprise long and/or general polymerization thing thermoplastic that continuous fiber is strengthened and at least one deck internal layer comprise it is not strengthened or general polymerization thing thermoplastic that random fiber is strengthened.
This method is especially useful under the situation that panel is made up of at least three layer laminate, and two outside layers comprises long and/or general polymerization thing thermoplastic that continuous fiber is strengthened and one deck sandwich layer at least, and it comprises general polymerization thing thermoplastic.The panel of even now may have desirable intensity and hot expansion property, and long fibre especially may have the tendency of the mark of leaving a trace.Such bottom helps confining surface, and making varied in thickness perhaps is that naked eyes can not be discovered.
This method further comprises provides second layer enamelled coating as nonferrous layer.This is convenient to produce colored panel.
The inventive method further comprises provides transparent light enamelled coating, face, and this is useful, because it provides high-quality finish, this visually allows the people joyful.
It will be appreciated by those skilled in the art that the present invention's feature in a certain respect described above can be applicable to others equally.
Hereinafter with reference to accompanying drawing by describing embodiment of the present invention by embodiment.In the accompanying drawing:
Fig. 1 a is depicted as five layers of compound before each layer combination;
Fig. 1 b is depicted as " blank " that five layers of compound by Fig. 1 a form;
Fig. 2 a is depicted as the panel of forming according to prior art processes in mould;
Fig. 2 b is depicted as the panel that forms according to one embodiment of the invention in vacuum mold;
Fig. 2 c is depicted as the panel that forms according to one embodiment of the invention in diel;
Figure 3 shows that process chart according to one embodiment of the invention;
Present embodiment relates to the car panel that the premium-type paint cover is provided.Fig. 1 a is depicted as each layer of the laminate blank 100 (" blank " refers to treat the object of molding) of the composition diagram 1b according to the present invention.Lamination comprises outermost layer 102a, the 102b of two-layer continuous fiber one-way reinforced polypropylene, the example of " thermoplasticity prepreg " known in the art (thermoplastic prepreg), and wherein fiber is orientated along first direction.For what those skilled in the art were familiar be, " length " fiber is often referred to the fiber that length surpasses about 1cm in this article, is different from " weak point " fiber of the about 0.4cm of length, is suitable for strengthening the plastics for the treatment of injection moulding like this.In the present embodiment, at least 4 to 10 centimetres fiber is that suitable (this promptly is known as continuous fiber) and these fibers are probably parallel with the surface of aspect 102a, 102b.
In each outermost fibre reinforced layer 102a, 102b the inside is internal layer 104a, the 104b of continuous fiber one-way reinforced polypropylene, and wherein fiber is orientated along second direction, and is general vertical with first direction.
Between internal layer 104a, 104b, be matrix or comprise the sandwich layer 106 of " natural " polypropylene (being that propylene is not strengthened with fiber).This provides polymer rich core.
The shop layer (lay-up) of blank 100 is symmetrical, and the both sides of core have the layer of similar number and each layer combination formation mirror image to make from the aspect order identical (the aspect back that promptly have first direction fiber be aspect with second direction fiber) of core to both sides.
Next step is an as-molded panel.What it will be understood to those of skill in the art that is that multiple mode as-molded panel is arranged, and wherein vacuum solidification and punching press will mainly be discussed together with some prior aries below.
Another problem is that fiber-reinforced material trends towards at the nook of mould gapped (holdoff).Such example is as shown in Fig. 2 a.Material can just not accepted the shape of mould 200a at an easy rate, thereby stays space 202,204 between drape molding material and mould 200a.The wedge angle that this means mould 200a can not be duplicated in as-molded panel.Fig. 2 a has also illustrated angle sharp-pointed more (being that radius of curvature is more little), just can see many more spaces 202,204.
According to one embodiment of the invention, next step of technology be step 304 be whether need to consider prefabricated.Usually when blank 100 desired shapes are complexity or spiral, the prefabricated needs.Prefabricatedly comprise step (being usually less than the fusing point of material) (step 306) (step 306) of heating blank 100, place mould 200a (step 308), 200b, 200c and punched blank 100 to being full of mould (step 310) blank 100.Such punching press can be finished by handheld tool.
Optionally, when not required prefabricated, blank is approximately placing mould (step 312) under the environment temperature.
According to this embodiment of the invention, although the aspect tiling forms blank 100, each layer be not in conjunction with or not " curings " arrive together, under about environment temperature, blank 100 places heated mold 200b, 200c, shown in Fig. 2 b, wherein outermost layer 102a as shown in the figure, but other each layer diagram not for the sake of clarity.Suitable mould 200b, 200c be by French BP341 Savoie Technolac, Roctool, 73377 Le Bourget You Lac produce.
At first consider the situation of vacuum solidification.The heating, vacuum mould 200b of Fig. 2 b comprises that conduit 206 is used for introducing heating or cooling liquid.In an alternate embodiment, mould can heat by electromagnetic induction method.
In the situation of using vacuum solidification, only the surface of mould 200b is heated.What those skilled in the art were familiar with is to be pressed into mould 200b by the vacuum that is applied to vacuum bag and to form panel.
In vacuum solidification, in case being capped, blank 100 places mould 100b, with regard to the sealed vacuum bag, form vacuum, and heat on the surface to mould 200b in step 314.Material softening also is melted in the surface of mould 200b.Mould 200b is heated to above the fusing point of material 100.In the present embodiment, polyacrylic fusing point is 170 ℃, and mould 200b is heated to 180 ℃, yet in other embodiments, can improve 30 ℃ to accelerate fusion process.
In case compound reaches 180 ℃ and sensible core, layer 102a, 104a, 106,104b, 102a just solidify fully.In the present embodiment, instrument is heated about 10 minutes to reach temperature required.Compound (step 316) carries out several minutes (being generally 5 minutes) in mould 200b temperature subsequently " resident " (dwell), the temperature maintenance of mould 200b is at 180 ℃, cool off about 10 minutes (step 318) again, in step 320, remove then, for comprising filling and about altogether 30 minutes complete cycle time of complete cycle of removing.
With respect to vacuum solidification faster alternative be impact moulding, but it will be appreciated by persons skilled in the art that the preparation cost of instrument is very high owing to need invest the instrument of " coupling ".The embodiment of diel 200c is by shown in Fig. 2 c.
Diel 200c comprises female part 200ci and male part 200cii, and both are incorporated into one and are used from punch components.In the described here embodiment, female part 200ci and male part 200cii are combined with cooling bath 206i, 206ii to be used for introducing heating or cooling fluid at the near surface that contacts with parts to be processed.
In impact moulding, in case blank 100 is loaded among the mould 200c, the latter is sometimes referred to as " instrument " (tool) in this article, heating and close die 200c in step 314.Sliding frame is used to control in the section bar (profile) that continuous fiber " slips into " (slip into) mould 200b.It will be appreciated by those skilled in the art that sliding frame comprises is roughly rectangular framework, and the predetermined tension that provides by spring makes rectangle material pressurized, clamping.Setting tension force makes material to slip into mould 200c by framework under predetermined tension.Can use suitable sliding frame such as Elkington Brothers of Birmingham, what UK produced.In case blank places mould 200c, mould 200c closure, heating makes material surpass its fusing point (step 306) to mould 200c, as the associated description of top vacuum solidification.Blank 100 is stopping to mould 200c heating (step 316) is preceding " resident " time, cooling die 200c then being arranged.Parts cool off (step 318) subsequently to the temperature (step 320) that can shift out safely from mould 200c.The whole circulation process can be in 2 minutes.
In punching press and vacuum solidification, the heating on surface is meaned that polymer is tending towards melting and flows in any space between the fiber of mould 200b, 200c and outermost layer 102a, 102b.
Two kinds of technologies all carry out moving with the 104a that guarantees at outermost layer 102a, b and internal layer, the fiber that b has only minimum under about 1bar " low pressure ".In an alternate embodiment, pressure is about 1 to 10bar to be suitable.
Panel takes out from mould and also carries out edging as required.In polyacrylic present embodiment, if japanning need carry out some preliminary treatment.Panel surface carries out flame treatment or plasma gun processing (step 322) and test to guarantee that surface tension surpasses 40 dyne/cm, and this is that high-quality is covered with paint, lacquer, colour wash, etc. needed paint adherence.Other polymer may not need such processing or need other processing.
Although very clearly still have thermal expansion by comprising the thermal expansion that fibre strengthening has reduced panel on the thickness of described panel, it is caused by variation of ambient temperature and not limited by fiber.Thermal expansion takes place really, does not have its degree of same polymer of reinforcement much lower but compare to.Unless the employing precautionary measures, otherwise this expansion is enough to make so-called fiber strengthened " vestige " (witness) to be presented at the surface.When panel expands and lacquer painting moves with it, will see " vestige ", but lacquer painting is caught a cold and can be got back to its origin-location.This effect meeting stays " vestige " of fiber in the lacquer decorations.It will be appreciated by those skilled in the art that the lacquer decorations that are used for automobile can accept the climate change test of standard before being used for automobile, this test can illustrate this effect.
Yet, in the present embodiment, also prime treatment is used for panel (step 324), form the low changeability epidermis that can not move along with the shape of panel.According to one embodiment of the invention priming paint comprise the sclerosis varnish (.
The panel that was coated with priming paint is before the lacquer of enameling dry (step 326).In case drying just is coated with the finish paint of layer of transparent light more.
Be understandable that and especially be applied to the panel of big plane of structure such as bonnet, ceiling and Sorte Nula by the embodiments described herein these are subjected to the goods of sun high heat load.
In an alternate embodiment, also regard as in the scope of the present invention, can have only three layers, skin comprise braided fiber, two-way fiber or " quasi-isotropic " (fiber orientation for vertically, intersect and along diagonal) fibre strengthening, foregoing sandwich layer is arranged.Alternatively, sandwich layer can not comprise natural polypropylene, but substitutes or regrown material with " random fiber " reinforced polypropylene, and (for example, automobile component that pulverizes such as bumper) has impurity as the paint speckle.In fact, composite bed can comprise non-polyacrylic thermoplastic, the selection that but it will be understood to those of skill in the art that polymer will be influential to technology, because the disposed of in its entirety temperature can be different, certain methods step (the especially processing of counter plate before japanning) will be not necessarily.
In addition, before japanning molded parts being carried out preliminary treatment may be not necessarily to some polymer.
This method can comprise extra " in the mould " technology, as applying decoration film, facing structure or circuit.
It can be the characteristic that the present invention chooses wantonly that panel has the discontinuous feature of surface curvature.
Claims (29)
1, a kind of method of making panel, described panel have discontinuous this feature of surface curvature at least from the teeth outwards, and this method comprises the steps:
Provide the first polymeric thermoplastic plastics long and/or parallel fibers reinforcement continuously as first strengthening layer;
Provide the second polymeric thermoplastic plastics as sandwich layer, this second polymer and first polymer are compatible;
Provide the first polymeric thermoplastic plastics long or parallel fibers reinforcement continuously as second strengthening layer;
Folded layer by layer strengthening layer is separated by sandwich layer each;
With this lamination lead-in surface board mold and heat this mould to the fusing point of predetermined at least polymer to solidify each layer and to form panel.
One of below 2, having at least according to the core material that the process of claim 1 wherein: i. about 70% second kind of polymer volume identical with two layers of reinforced material approximately by volume with ii..
3, make the method for panels according to claim 1 or 2, comprise that further the panel of molding is carried out flame treatment, corona discharge or plasma gun to be handled.
4, according to the method for the described manufacturing panel of aforementioned arbitrary claim, wherein first polymer is identical or essentially identical polymer with second polymer.
5, according to the method for the described manufacturing panel of aforementioned arbitrary claim, wherein molding carries out in vacuum solidification mould or diel.
6, according to the method for the described manufacturing panel of aforementioned arbitrary claim, wherein at least a portion of mould is heated.
7, the method for manufacturing panel according to claim 6 heats the finished surface that will be used for a side of panel that will japanning is carried out molding at least.
8,, further comprise at least a portion of cooling die according to the method for the described manufacturing panel of aforementioned arbitrary claim.
9, the method for manufacturing panel according to claim 8, wherein only finished surface is cooled.
10,, comprise providing sandwich layer to make it account for about 50% of plate thickness according to the method for the described manufacturing panel of aforementioned arbitrary claim.
11, according to the method for the described manufacturing panel of aforementioned arbitrary claim, comprise the strengthening layer that provides more than two-layer.
12, the method for manufacturing panel according to claim 11, each side that is included in sandwich layer all provides two layers of reinforced material, wherein outermost layer along the second direction binding fiber perpendicular to first direction, is arranged sandwich layer along first direction binding fiber and internal layer strengthening layer between the internal layer strengthening layer.
13, according to the method for the described manufacturing panel of aforementioned arbitrary claim, one or more layers strengthening layer of its center core layer one side can be arranged as basically and become the minute surface symmetry with one or more layers strengthening layer of sandwich layer opposite side.
14,, comprise one or more layers strengthening layer with fiber of laying along two mutually perpendicular directions being provided and/or comprising one or more layers strengthening layer of laying fiber with diagonal by quasi-isotropic method in addition according to the method for the described manufacturing panel of aforementioned arbitrary claim.
15, the method for manufacturing panel according to claim 14 knitted together it before in fiber being attached to layer.
16, according to the method for the described manufacturing panel of aforementioned arbitrary claim, comprising the sandwich layer with reinforcing fiber is provided.
17, according to the method for the described manufacturing panel of aforementioned arbitrary claim, its SMIS is made up of the terminal thing of recycled materials, industry abrasive material again or recycling.
18, according to the method for the described manufacturing panel of aforementioned arbitrary claim, it comprises the manufacturing that panel is used for the vehicles.
19, a kind of panel of forming by laminated composite materials, it comprises: comprise the thermoplastic core of predetermined polymer by volume, with comprise continuous fiber reinforced predetermined polymeric thermoplastic plastics covering, long fibre wherein is parallel with tectal surface orientation, internal layer lining cap rock part at least covers each surface, and wherein each layer all solidifies in heated mold.
20, according to the panel of claim 19, wherein lamination comprises at least three layers, and two outside layers comprises long or general polymerization thing thermoplastic that continuous fiber is strengthened and one deck internal layer at least, and it comprises the predetermined polymeric thermoplastic plastics of not strengthening.
21, according to the panel of claim 19 or 20, its center core layer account for predetermined polymer by volume 70% and by volume panel 50% in one of at least.
22, a kind of method of coating with lacquer coating fiber reinforced plastics panel comprises that coating contains the ground floor priming paint of varnish, makes ground floor form the rigidity coating, is coated with second layer paint vehicle again.
23, according to the method for the lacquer coating fiber reinforced plastics panel of claim 22, wherein plastics comprise the mixed structure of multiple composite plastics material.
24, according to the method for the lacquer coating fiber reinforced plastics panel of claim 22 or 23, further comprise providing second layer enamelled coating as nonferrous layer.
25, according to each the method for lacquer coating fiber reinforced plastics panel of claim 21-24, further comprise transparent light coating is provided.
26, a kind of method of making panel, basically such as here description and 1 to 3 elaboration of accompanying drawing.
27, a kind of panel, basically such as here description and 1 to 3 elaboration of accompanying drawing.
28, a kind of composite plastic, basically such as here description and 1 to 3 elaboration of accompanying drawing.
29, a kind of lacquer is coated with the method for reinforced plastics panel, basically such as here description and 1 to 3 elaboration of accompanying drawing.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0416198.0 | 2004-07-20 | ||
| GB0416197.2 | 2004-07-20 | ||
| GB0416197A GB0416197D0 (en) | 2004-07-20 | 2004-07-20 | Composite plastic and related manufacturing methods |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN101031420A true CN101031420A (en) | 2007-09-05 |
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Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
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| CN 200580030198 Pending CN101031420A (en) | 2004-07-20 | 2005-07-20 | Recyclable composite plastic and related manufacturing methods |
Country Status (2)
| Country | Link |
|---|---|
| CN (1) | CN101031420A (en) |
| GB (1) | GB0416197D0 (en) |
Cited By (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102006986A (en) * | 2008-03-07 | 2011-04-06 | 空中客车公司 | Method and device for producing a curved section made from composite material and resulting section |
| CN102173060A (en) * | 2011-02-24 | 2011-09-07 | 江苏大学 | Device and method for manufacturing carbon fiber reinforced composite construction member |
| CN102510800A (en) * | 2009-09-14 | 2012-06-20 | 亚历山大·弗格森 | An improved method of and apparatus for making a composite material |
| CN103085287A (en) * | 2011-11-02 | 2013-05-08 | 通用汽车环球科技运作有限责任公司 | One-piece fiber reinforcement for a reinforced polymer combining aligned and random fiber layers |
| CN103568434A (en) * | 2012-08-09 | 2014-02-12 | 佛吉亚汽车内部系统公司 | Plastic panels for motor vehicles and methods for making the same |
| CN105377523A (en) * | 2013-07-12 | 2016-03-02 | 布罗泽汽车部件制造哈尔施塔特有限公司 | Method for producing structural component for motor vehicles from organo-sheet |
| CN105729826A (en) * | 2014-12-10 | 2016-07-06 | 磁震科技开发股份有限公司 | Composite decorative structure with micro-three-dimensional surface and manufacturing method of composite decorative structure |
| CN106273929A (en) * | 2015-05-26 | 2017-01-04 | 句容市百事特复合材料有限公司 | Composite board and the preparation technology thereof of sandwich is made with the enhancing of continuous fiber top layer, LFT |
| JP2019031007A (en) * | 2017-08-07 | 2019-02-28 | トヨタ自動車株式会社 | Resin structure |
| CN111282789A (en) * | 2018-12-07 | 2020-06-16 | 上海航空电器有限公司 | Surface coating pretreatment method for formation lamp with stealth performance |
| CN115515780A (en) * | 2020-04-06 | 2022-12-23 | 帝人株式会社 | Vehicle component unit and method for producing a vehicle component unit |
-
2004
- 2004-07-20 GB GB0416197A patent/GB0416197D0/en not_active Ceased
-
2005
- 2005-07-20 CN CN 200580030198 patent/CN101031420A/en active Pending
Cited By (17)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN102006986A (en) * | 2008-03-07 | 2011-04-06 | 空中客车公司 | Method and device for producing a curved section made from composite material and resulting section |
| CN102006986B (en) * | 2008-03-07 | 2014-01-08 | 空中客车公司 | Method and device for producing a curved section made from composite material and resulting section |
| CN102510800A (en) * | 2009-09-14 | 2012-06-20 | 亚历山大·弗格森 | An improved method of and apparatus for making a composite material |
| CN102173060A (en) * | 2011-02-24 | 2011-09-07 | 江苏大学 | Device and method for manufacturing carbon fiber reinforced composite construction member |
| CN103085287A (en) * | 2011-11-02 | 2013-05-08 | 通用汽车环球科技运作有限责任公司 | One-piece fiber reinforcement for a reinforced polymer combining aligned and random fiber layers |
| CN103568434A (en) * | 2012-08-09 | 2014-02-12 | 佛吉亚汽车内部系统公司 | Plastic panels for motor vehicles and methods for making the same |
| US10807299B2 (en) | 2013-07-12 | 2020-10-20 | Brose Fahrzeugteile Gmbh & Co. Kommanditgesellschaft, Hallstadt | Method for producing a structural component for motor vehicles from an organo-sheet |
| CN105377523A (en) * | 2013-07-12 | 2016-03-02 | 布罗泽汽车部件制造哈尔施塔特有限公司 | Method for producing structural component for motor vehicles from organo-sheet |
| US10919210B2 (en) | 2013-07-12 | 2021-02-16 | Brose Fahrzeugteile Gmbh & Co. Kg, Hallstadt | Organo-sheet for motor vehicles |
| CN112936726A (en) * | 2013-07-12 | 2021-06-11 | 博泽(班贝格)汽车零部件欧洲两合公司 | Method for producing a structural component of a motor vehicle |
| CN105729826A (en) * | 2014-12-10 | 2016-07-06 | 磁震科技开发股份有限公司 | Composite decorative structure with micro-three-dimensional surface and manufacturing method of composite decorative structure |
| CN106273929A (en) * | 2015-05-26 | 2017-01-04 | 句容市百事特复合材料有限公司 | Composite board and the preparation technology thereof of sandwich is made with the enhancing of continuous fiber top layer, LFT |
| CN106273929B (en) * | 2015-05-26 | 2018-09-25 | 句容市百事特复合材料有限公司 | Make the composite board and its preparation process of sandwich with the enhancing of continuous fiber surface layer, LFT |
| JP2019031007A (en) * | 2017-08-07 | 2019-02-28 | トヨタ自動車株式会社 | Resin structure |
| CN111282789A (en) * | 2018-12-07 | 2020-06-16 | 上海航空电器有限公司 | Surface coating pretreatment method for formation lamp with stealth performance |
| CN115515780A (en) * | 2020-04-06 | 2022-12-23 | 帝人株式会社 | Vehicle component unit and method for producing a vehicle component unit |
| CN115515780B (en) * | 2020-04-06 | 2024-03-22 | 帝人株式会社 | Vehicle component unit and method for producing a vehicle component unit |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0416197D0 (en) | 2004-08-18 |
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Application publication date: 20070905 |