CN110281454A - 具有局部纤维插入件的载体和方法 - Google Patents

具有局部纤维插入件的载体和方法 Download PDF

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Publication number
CN110281454A
CN110281454A CN201910542960.3A CN201910542960A CN110281454A CN 110281454 A CN110281454 A CN 110281454A CN 201910542960 A CN201910542960 A CN 201910542960A CN 110281454 A CN110281454 A CN 110281454A
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CN
China
Prior art keywords
insertion piece
fiber
polymer material
material block
polymer
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.)
Pending
Application number
CN201910542960.3A
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English (en)
Inventor
F·布雷曼德
E·肖邦
亨利·E·理查德森
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Zephyros Inc
Original Assignee
Zephyros Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Zephyros Inc filed Critical Zephyros Inc
Publication of CN110281454A publication Critical patent/CN110281454A/zh
Pending legal-status Critical Current

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    • B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
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    • B29C44/18—Filling preformed cavities
    • B29C44/188—Sealing off parts of the cavities
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    • D06N3/00—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof
    • D06N3/12—Artificial leather, oilcloth or other material obtained by covering fibrous webs with macromolecular material, e.g. resins, rubber or derivatives thereof with macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds, e.g. gelatine proteins
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Abstract

本申请涉及一种具有局部纤维插入件的载体和方法。具体地，涉及一种包括载体的用于制品的结构补强，其包括：(i)具有外表面的聚合物材料块体；和(ii)具有外表面、并包括具有以预定方式排列的多个有序纤维的至少一种延长纤维排列的至少一种固结纤维插入件。纤维插入件预见在预定位置连接聚合物材料块体，用于承载在预定位置受到的预定负荷(由此有效地向该预定位置提供局部补强)。纤维插入件和聚合物材料块体的材料、结构、或材料与结构二者相容，用于使纤维插入件至少部分地连接至聚合物材料块体。在载体的至少一部分上设置的将会是可活化材料块体。

Description

具有局部纤维插入件的载体和方法
本申请是申请日为2014年10月21日、申请号为201480069942.3、发明名称为“具有局部纤维插入件的载体和方法”的中国专利申请的分案申请。
技术领域
本发明总体上涉及制品的结构补强、密封和/或隔挡，更特别地涉及机动车通过应用粘结于例如机动车等运输车辆的空腔中的改进补强的结构补强。
背景技术
在很多工业中有不断的努力来减轻制品的重量。在很多实例中，这通过与此前的材料或结构相比具有较低密度、较薄的部件厚度或二者兼具的材料的选择而实现。结果，有削弱制品的可能，以及由此对结构补强的需求。
在机动车制造领域，普遍使用车体结构腔内的结构补强。例如，已普遍在车体结构的腔内使用在一个或多个外表面上负载可活化材料(activatable material)的相对刚性的成型聚合物载体。对于某些可活化材料，一旦活化(例如通过来自涂布烘箱的热)，该可活化材料可膨胀并接合至将腔限定的表面。
为了选择性地控制制品补强结构的性质，已教导使用包括多种用于载体用材料的组合的混合补强结构。参见例如美国专利号8,430,448，此处通过引用将其明确并入用于所有目的。也参见专利合作条约(PCT)申请号WO 2010/054194，此处通过引用将其明确并入用于所有目的。
在机动车工业中，计算机建模(例如有限元分析)的使用已广泛用于模拟车辆碰撞，并用于对车辆的特定部分将如何响应碰撞进行模型化。
尽管有上述努力，仍保持对可选的载体结构的需求。例如，仍保持对以下可选载体结构的需求，该可选载体结构利用即使不同但仍然大致(generally，通常)互相相容(例如化学和/或物理相容)、因而无需粘结剂就可连接在一起的不同材料的组合。也保持对以下可选载体结构的不断需求，该可选载体结构利用各自含有大量聚合物部分(例如非金属部分)的不同材料的组合而使得可达到重量减轻。也保持对以下可选载体结构的不断需求，该可选载体结构利用在与由不同各材料限定的载体部分通常连续的界面区域处连接在一起的不同材料的组合。也保持对通过载体内特定材料的使用而可利用一种或多种局部化补强的可选载体的不断需求，其可在不存在对用于赋予局部补强的结构特征(例如肋)的需求下获得。
复合结构的实例在PCT申请号WO 2007/008569、美国专利申请公开号2011/0039470和2012/0251863、以及美国专利号7,581,932中说明，均通过引用将其并入用于所有目的。也参见美国专利号6,855,652和7,318,873，和美国专利申请公开号2003/0039792、2010/0289242、2011/0278802和2009/0202294，通过引用并入用于所有目的。
本申请要求2013年10月21日提交的英国专利申请号1318595.4和2013年12月17日提交的美国临时申请号61/916,884的优先权利益，此处将这些申请的内容通过引用并入用于所有目的。
发明内容
上述需求的一种或多种通过本文教导而满足，教导考虑可有利地利用用于密封、隔挡和/或结构地补强各种制品，并特别地用于结构地补强例如机动车等运输车辆的改进结构和方法。
一方面，教导考虑用于制品的结构补强，该结构补强包括载体，所述载体包括：(i)具有外表面(例如通常为平滑和/或连续的外表面)的聚合物材料块体(a mass ofpolymeric material)；和(ii)具有外表面并包括至少一种有多个可按预定方式排列的有序纤维(例如具有可为轴向排布的连续纤维的块体)的延长纤维排列的至少一种固结纤维插入件(consolidated fibrous insert)。预见此纤维插入件在预定位置连接聚合物材料块体，用于承载在预定位置处受到的预定负荷(由此有效地对该预定位置提供局部补强)。纤维插入件和聚合物材料块体的材料、结构、或二者相容，用于使纤维插入件至少部分地结合至聚合物材料块体。在载体的至少一部分上设置的将会是可活化材料(例如可膨胀材料)的块体。例如，可活化材料的块体可选择性地施用在聚合物材料或纤维插入件的块体的一个或两个外表面的至少一部分上。可活化材料的块体可通过外部刺激而活化以膨胀(例如至少部分地填充间隙或腔)，并也可固化来形成接合至制品的至少一个表面的粘合剂。期望地，纤维插入件的外表面与聚合物材料块体的外表面至少部分地共同延伸和连续。
一方面，教导考虑用于制品的结构补强的制作方法。方法可包括将具有外表面并包括至少一种延长的纤维排列(例如具有可为轴向排布的连续纤维的块体)的至少一种纤维插入件(其可为固结的和/或可具有预定的三维形状构造)插入工具的腔中的步骤。可采用以下步骤：将与纤维插入件接触的聚合物材料块体成型，使得所得的聚合物材料的成型块体整体地连接纤维插入件，并且纤维插入件的外表面(其通常可为平滑的和/或连续的)与所得的聚合物材料的成型块体的外表面至少部分地共同延伸和连续。可采用将可活化材料的块体选择性地施用在所得的聚合物材料或纤维插入件的块体的一个或两个外表面的至少一部分上的另一步骤。可活化材料的块体可通过外部刺激而活化，用于膨胀来至少部分地填充间隙或腔，并可固化来形成接合至制品的至少一个表面的粘合剂。
另一方面，本文的教导考虑包含用于形成纤维补强热塑性片的纤维插入件(例如成形连续纤维补强热塑性片(formed continuous fiber reinforced thermoplasticsheet)，或纤维插入件)的装置，由此热塑性片接合至聚合物材料块体(例如附加的强化材料)，并且装置进一步包括可活化材料(其可为热活化和/或可发泡材料)。可活化材料可为可发泡和/或粘合性材料。聚合物材料块体可提供从纤维补强热塑性片的一侧或两侧延伸的补强肋。聚合物材料块体可包含短纤维(例如长度小于约10mm，或甚至小于约5mm)填充的聚酰胺。可活化材料可设置在纤维补强热塑性片和/或聚合物材料块体的选择的表面上。可活化材料可为热活化的热固性树脂。热活化的热固性树脂可为环氧树脂。
本文的教导进一步考虑装置的制造方法，包括将纤维补强热塑性片热成形，向热成形片提供聚合物材料块体，并进一步向热成形热塑性片和/或聚合物材料块体的表面提供可活化材料。聚合物材料块体可通过将热成形片放置在模具中，并将聚合物材料块体注射到热成形片上而提供。可活化材料可通过向纤维补强热塑性片和聚合物材料块体上挤出或注射成型而提供。可活化材料可为粘合性和/或可发泡材料。聚合物材料块体可为短纤维填充的聚酰胺。可活化材料可为热活化可发泡热固性树脂。可活化材料可含有热活化固化剂。
本文的教导也考虑一种组件，其包含接合至附加的强化材料(例如聚合物材料块体)的成形连续纤维(例如纤维插入件)补强热塑性片，并进一步含有热活化材料(heatactivated material)(例如可活化材料)。热活化材料可为可发泡和/或粘合性材料。附加的强化材料可提供从成形连续纤维补强热塑性片的一侧或双侧延伸的补强肋。附加的强化材料可包含短纤维填充的聚酰胺。热活化材料可设置在连续纤维补强热塑性片和/或附加的强化材料的选择的表面上。可活化材料可为热活化热固性树脂。热活化热固性树脂可为环氧树脂。
本文的教导进一步提供用于制造组件的方法，其包括将连续纤维补强热塑性片热成形，向热成形片提供附加的强化材料，并进一步向热成形热塑性片和/或附加的强化材料的表面提供热活化材料。附加的强化材料可通过将热成形片放置在模具中并向热成形片上注射附加的强化材料而提供。可活化材料可通过向热成形片的双组件材料和附加的强化材料上挤出或注射成型而提供。可活化材料可为粘合性和/或可发泡材料。附加的强化材料可为短纤维填充的聚酰胺。可活化材料可为热活化可发泡热固性树脂。可发泡热固性树脂可含有热活化的固化剂。
本教导也考虑用于在腔中提供补强的方法，包括将根据本教导的组件放置在腔中并加热以活化此可活化材料。腔可为车体壳中的腔，且加热在140℃至220℃的温度下发生。
本文的教导进一步提供本文教导的组件在用于机动车或航空航天工业的组件的生产中的用途。
根据本教导制作的部件具有运输车辆(例如机动车)中的应用。例如，如上文所述，此类部件可使用可活化材料，其在活化(例如通过合适的能量源，例如来自涂料烤箱的热)时将膨胀并固化以形成发泡材料。所得的活化材料可具有用于赋予结构刚性或补强的应用(即，可能当作是结构泡沫体；结构泡沫体的实例包括但不限于可从L&L Products在L5204、L5207、L5214、L5234、L5235、L5236、L5239、L5244、L5505、L5510、L5520、L5540、L5800、L5810和L8514的名称下获得的产品)。所得的活化材料可具有密封和/或减少噪声的应用。所得的活化材料可膨胀至其原始体积的至少约50％、100％、200％、400％、600％或甚至1000％。所得的活化材料可从其原始体积膨胀，但以低于其原始体积的约2500％、2000％，或甚至低于约1500％的量膨胀。
有利地，本文的教导提供对载体的结构和/或形成的改进方案，因为可利用多种不相似的材料，并将展现遍及载体总体上连续的单一结构。本教导的载体的暴露表面可大致平滑和/或连续。例如，在本文的教导以内考虑的是具有聚合物部分、局部补强部分、和聚合物部分与局部补强部分之间的界面部分的载体，其中聚合物部分、界面部分和局部补强部分通常为平滑和/或连续结构。界面部分可包括由聚合物部分和局部补强部分的聚合物材料限定的互穿网络。界面部分可包含聚合物部分的聚合物和局部补强部分的聚合物之间的化学键。按这样的方式，所得的载体可由此不展现裸眼可见的汇合线(knit line)。所得的载体也可不展现跨越界面部分的对裸眼可见的空隙或间断。
本文的教导也使得能设计一系列易于制造的包含局部补强区域的载体。
附图说明
图1是根据本教导的一种说明性部件的部分的侧视截面图。
图2是根据本教导的另一种说明性部件的部分的侧视截面图。
图3是根据本教导的还一种说明性部件的部分的侧视截面图。
图4a是根据本教导的一种说明性载体的俯视透视图。
图4b是图4a的载体的底视透视图。
图5是本教导的纤维插入件的一种说明性布局的分解透视图。
图6a是根据本教导的说明性纤维插入件的透视图。
图6b是包含图6a的纤维插入件的说明性部件的透视图。
图7a是根据本教导的另一说明性纤维插入件的透视图。
图7b是包含图6a的纤维插入件的说明性部件的透视图。
图8是说明根据本教导的说明性部件的形成的图表。
图9是成型方法的图解。
图10和11比较了具有玻璃纤维补强的聚酰胺的本发明产品和钢的性质。
具体实施方式
连续纤维补强热塑性材料包含连续的纤维，其可为包埋在热塑性基质中的玻璃纤维、碳纤维或芳族聚酰胺纤维。纤维可为个别纤维的丝束，或可为纺织或非纺织材料。材料典型地获取为用于后续成形(forming)的材料的片，并且连续纤维优选处于沿着片的Y轴，并沿着片的长度连续。连续纤维补强热塑性材料可按其本身而使用，或者任选地可按与其它材料一起的复合物使用。它们可通过可热活化并也可发泡的结构粘合剂的途径接合至机动车或航空器结构。例如，材料可层压至例如短纤维填充的热塑性材料等其它材料，和/或它们可层压至可为热塑性或热固性材料的可发泡材料。连续纤维补强的材料通常为完全浸渍的平板并且是基本无空气和空隙的固结材料。材料通常获取为用于后续成形的材料的片，并且连续纤维优选处于沿着片的Y轴，并沿着片的长度连续。
如果为片，则片通常为0.2至6.0mm厚，并可为任意希望的宽度，我们已发现有用的宽度为600至1200mm。纤维可为玻璃纤维、碳纤维或芳族聚酰胺纤维，并且我们优选片的纤维含量为45至75体积％。我们发现具有这些性质的片可容易地热成形而产生用在车辆中的任一组件，或与其它片材料一起热成形以形成用在车辆中的组件。材料也可形成载体，用于后续接合至进一步的材料，供用作组件。
如同已指明的，连续纤维可为玻璃纤维、碳纤维或芳族聚酰胺纤维。包埋连续纤维的热塑性材料的选择将取决于组件最终的用途和期望的性质。可选择出热塑塑料的优选的热塑塑料为聚烯烃，例如各种形式的聚乙烯、聚丙烯、烯烃共聚物、聚合橡胶。可使用的其它热塑塑料包括聚酰胺、聚酰亚胺、热塑性聚酯和聚酮。连续纤维补强的材料可通过在合适的模具中热成形而容易地定形(shape)。例如，片可放置在模具中，并加热至热塑性材料的软化温度，并施加压力以便在模具中将材料定形至所需的形状，一旦材料冷却至低于软化点时就保持形状。发现这样的技术在生产复杂形状的组件中有用。此方法也可用于通过在热成形连续纤维补强的热塑塑料片用的温度下热接合材料，或通过使用在热成形用的温度下活化的热活化粘合剂，来生产连续纤维补强的热塑塑料与其它材料的层压体。
定形的连续纤维补强产品可在其全部或部分表面上层压至例如附加的补强材料和/或可发泡材料等其它材料，以在其全部或部分表面上提供可发泡材料，以提供按上文所述方式有用的汽车的结构补强用的可发泡组分。用于提供结构补强的优选的材料为可热固化并可热发泡的材料，其为热塑性的，并可在低于固化发生的温度下处理。此类产品的实例为可从L&L Products在L5204、L5207、L5214、L5234、L5235、L5236、L5239、L5244、L5505、L5510、L5520、L5540、L5800、L5810和L8514的商品名下获得的产品。
在特别的实施方案中，连续纤维补强热塑性材料可在压机或模具中被热成形至所需的形状。然后热成形材料可放置在模具中，该模具为将要通过在热成形材料上二次成型而提供的附加材料提供空间。可将附加材料引入模具中，并接合至热成形材料。附加材料可为热塑性的，且模具可使得附加材料定形，以提供例如从热成形材料伸出的补强肋。肋或其它形状可设置在热成形材料的一侧或双侧上。肋或其它形状可设置在热成形连续纤维补强热塑性材料的一侧或双侧上。材料优选通过注射成型提供，并且优选的附加材料为玻璃填充的尼龙。
在本教导的另一方面，考虑用于制品的结构补强。结构补强包括载体，载体包括具有外表面并包括第一聚合物材料(例如第一热塑性材料)的聚合物材料块体。载体也包括至少一种具有外表面的固结纤维插入件(其可具有插入件内的纤维预定排序和/或可具有三维形状构造)。所述至少一种固结纤维插入件包括分布在第二聚合物材料(例如第二热塑性材料)的粘性块体中的至少一种延长纤维排列(例如具有连续纤维的块体，其可为有序排列，例如通过相互大致轴向排布)。纤维插入件以预定位置连接第一聚合物材料块体，用于承载在预定位置处受到的预定负荷。纤维插入件和第一聚合物材料块体包括相容的材料、结构、或二者，用于使纤维插入件至少部分地连接至聚合物材料块体。结构补强也包括选择性地施用在聚合物材料或纤维插入件的块体的一个或两个外表面的至少一部分上的可活化材料的块体(例如，在载体的外周表面上，在载体的腔内，或二者兼有)。可活化材料的块体能通过外部刺激(例如热、水分、辐射或其它)而活化用于膨胀，并能固化以形成接合至制品的至少一个表面的粘合剂。期望地，纤维插入件的外表面可与聚合物材料块体的外表面至少部分地共同延伸和连续。
如上所述，第一和第二聚合物材料可为热塑塑料。例如，第一和第二材料可为聚酰胺、聚烯烃(例如聚乙烯、聚丙烯或其它)、聚碳酸酯(盐)、聚酯(例如聚对苯二甲酸乙二酯)、热塑性聚氨酯，或其任意组合。优选使用聚酰胺(例如聚酰胺6、聚酰胺6,6、聚酰胺9、聚酰胺10、或聚酰胺12等)。第一和第二材料通常相互相容，因为它们之间能形成机械或其它物理相互连接(例如显微相互连接)，它们之间能形成化学键，或二者兼有。例如，第一和第二材料可为，当加热至高于其熔点和/或其软化点时，它们融合在一起(例如在没有任何粘合剂的存在下)。第一聚合物材料、第二聚合物材料或二者可由短切纤维(例如短切玻璃纤维)填充，存在的量可为约25至约40(例如约30至约35)重量百分数的短切纤维。此类纤维的平均长度可低于约20mm、低于约10mm或甚至低于约5mm。它们可随机取向。第一和第二材料可没有任何金属材料。
纤维插入件可包含以包含分布在第二聚合物材料的粘性块体中的多个单独纤维的方式固结的一层或多层(例如它们可具有2、3、4、6层或更多层)。单独的纤维可按预定的有序排列分布在第二聚合物材料的基质中。优选至少部分纤维在其排列中有序(如以大致相互有序的关系，例如大致平行或单向或其它大致轴向排布)，并由此在第二聚合物材料中非随机分布。多个层可固结在一起，由此形成包括多层的粘性块体。多层可固结，从而以三维定形的插入件的形式形成预定的形状。例如，纤维插入件可使用多个层，多个层可包含相互大致平行或大致单向取向、并分布在大致连续的聚合基质中(例如在第二聚合物材料的连续基质中)的多个延长纤维(例如具有至少1cm、3cm或甚至5cm的长度)。纤维可为矿物纤维(例如玻璃纤维，例如E-玻璃纤维、S-玻璃、B-玻璃或其它)、聚合物纤维(例如芳族聚酰胺纤维、纤维素纤维或其它)、碳纤维、金属纤维、天然纤维(例如源自农业来源)，或其它。期望地，纤维为玻璃纤维。多个延长纤维可大致相互平行取向。它们可编结(braided)。它们可搓捻。纤维的集合可为纺织和/或非纺织的。纤维的平均直径可为约1至约50微米(例如约5至约25微米)。纤维上可具有合适的上浆涂层。纤维可按大致至少约20重量％、30重量％、40重量％或甚至50重量％的量存在于各层中或纤维插入件中。纤维可按低于约90重量％、80重量％或甚至约70重量％的量存在于各层中或纤维插入件中。例如，纤维可按约50重量％至约70重量％的量存在于各层中或纤维插入件中。纤维以重量计的含量可根据ASTM D2584-11来测定。用于纤维插入件层的带和/或片可通过挤出、拉挤或其它方式制成。以此方式，可能获得带和/或片中的有序纤维。本文的方法可包括用聚合基质的材料浸渍纤维块体、并使所得的浸渍材料经过模头(例如加热的模头)从而纤维块体由大致连续的聚合基质材料的块体施用的步骤。以这种方式，也可能获得纤维相互之间的期望排序。
纤维插入件的各层可为片、带或其它形式。片和/或带中的纤维优选可具有相互之间有序的关系。例如，纤维可相互大致平行和/或单向地取向。当既爱那个片、带或其它形式的层的多层固结以形成多重纤维插入件时，优选纤维插入件的至少一层表现有序的关系，与随机关系相对，例如在纤维垫中所见的，其通常使用相互随机铺置的短切纤维。
可能将纤维插入件的层设置为卷轴上的口。各层可具有至少约0.1mm或至少约0.2mm的厚度。各层可具有低于约0.5mm或低于约0.4mm的厚度。例如，各层的厚度可为约0.2至约0.3mm。单独的层的部分或全部可在其机械性质上为各向异性。例如，其在纵向上可表现出相对高的挠曲模量和/或强度，但在横向上为较低的挠曲模量和/或强度，反之亦然。
纤维插入件可包括多个编织条(woven strip)。例如，可包括多个交织的条，各条具有至少约1mm、至少约2mm、或甚至至少约3mm的宽度。可包括多个交织的条，各条具有低于约10mm、低于约8mm、或甚至低于约6mm的宽度。编织条可通过聚合基质材料，例如插入件的聚合物材料的连续基质而保持在一起。由此，条依靠聚合物材料而相互固定在预定的位置。优选至少一部分条可各自包含期望地在聚合物材料的连续基质中以相互有序的关系排列的多个延长纤维。然而，可能一个或多个条可包含具有相互随机取向关系的纤维，例如源自通常的纤维垫。形成织物用的条可通过将带、片或其它形式撕成合适的宽度以形成条而制作。可选地，可能条以所需的宽度拉挤、挤出或其它成形(如本文所述)。
限定纤维插入件的材料可表现出根据ASTM D790-10的至少约450MPa挠曲模量(例如，其可在约500至约1100MPa的范围)。纤维插入件的材料可表现根据ASTM D790-10的至少约5GPa、10GPa、20GPa或甚至至少约25GPa的挠曲模量(例如，其可在约30至约35GPa的范围)。
纤维插入件可使用聚合基质用的完全致密化的聚合物。纤维插入件可具有如通过ASTM D2734-09所测定的低于插入件的约10体积％的空隙含量，并更优选低于约5％，或甚至低于约2％或1％。纤维插入件的密度可低于钢密度的约40％，低于钢密度的约33％，或甚至低于普通碳钢密度的约25％。
纤维插入件可制作来包括多个相邻的层。相邻层可具有相互相同或不同的纤维取向。纤维插入件可包括邻接非纺织层的纺织层。纤维插入件可包括邻接另一纺织层的纺织层。纤维插入件中的纺织层的纺织图案在此类纺织层之间可相同或不同。条的宽度在相邻层之间可不同。相邻层的厚度可相同或不同。
纺织图案的实例包括平织、斜纹纺织或其它。重叠的条可通常相互垂直或以别的角度纺织。织物可包括多个经纬条。经条对纬条的比例可为约30:70至约70:30的范围。例如其可为约50:50。可能经纬构件的条可具有大致相同的宽度。经条和纬条宽度相互差异可为10％、20％、30％以上。经条和纬条宽度相互差异可为约70％、60％、50％以下。
本文的纤维插入件中的带和/或片的各相邻层可取向为具有按相对于相邻层的纤维以不同的预定方向排布的纤维(即包埋在带和/或片的聚合基质中的纤维)。一层中的纤维可相对于相邻层中的纤维大致成一角度(例如，层之间的纤维取向的轴的差异可为约10至约90°，例如以X-层的形式)。例如，一种多层结构可包括可具有以第一面的第一方向取向的纤维的一层，和按纤维大致处于平行于第一面的第二面、但以大约90度角取向的相邻层。
期望地，相邻层的各层连接在一起作为粘性块体。例如，各层可通过各自层的聚合物材料接合在一起以形成一系列连续层。层可在没有任何粘合剂的情况下接合在一起。
纤维插入件可具有其中包含或附加的一种或多种结构特征。例如，可使用一种或多种紧固件(例如一种或多种螺纹紧固件)。一种或多种手柄可形成或整合在纤维插入件中(例如用于提供供涂布液经过的间隙)。一种或多种铆钉(例如自冲铆钉、盲铆钉或二者)可整合在插入件中。一种或多种金属板(metal blank)可整合在插入件中，其可适配来在所得的部件上提供位置用于点焊。一种或多种钉可整合在插入件中(例如具有基体，其可具有本文定义的孔洞，其处于纤维插入件中或表面上，并具有从基体向外延伸的杆(例如螺杆))。
如上所述，纤维插入件可具有预定的形状。形状可为碰撞的计算机模拟步骤期间进行的一种或多种计算、某种应力状态或其它的结果，并可选择来在部件预定区域中提供附加的局部补强，该部件预定区域将要受到从此类计算中确定的预测应力条件。本文的纤维插入件可包括在部分或全部长度上大致为正弦的几何形状、通过横穿壁连接在一起的一对隔开的壁、一个或多个壁架和/或台阶、凹陷的表面部分、凸出的表面区域、或一种或多种孔洞中的一种或任意组合。如上所述，本文的纤维插入件可具有三维构造，与通常平面的构造形成对比。
纤维插入件的特征可在各应用之间不同。本教导的益处之一是纤维插入件的层可选择为满足特定应用的需求(例如对计算机模拟的模型化(例如计算机碰撞或应力状态模拟)作出反应)。基于应用需要的性能，插入件可单独构建以包括多个层。此外，本文教导的另一益处是局部补强可通过将插入件定位在指明需要附加局部补强的特定位置而达到(例如对计算机模拟(例如计算机碰撞或应力状态模拟)作出反应)。本文的教导由此为技术人员提供出乎意料的扩展能力来选择性地调整结构补强的性能。教导也考虑通过计算机模拟来确定在碰撞中或在特定应力状态下预计载体将承载预定负荷的位置的模型化的使用。基于此类模型化的结果，可确定纤维插入件应定位的位置。同样，基于此类模型化的结果，可查明纤维插入件中纤维的取向和/或带或片的各相邻层的选择。此后基于此类模型化得出的设计可制作部件。使用此类步骤的方法由此也在本教导之内。
结构补强的载体可为，纤维插入件的外表面与聚合物材料块体的外表面大致共同延伸。这可遍及纤维插入件边界的部分或全部。也预见纤维插入件可具有各自暴露并由此在所得的部件中可见的对向表面。例如，纤维插入件可具有暴露的外表面和暴露的内表面。由此，纤维插入件可仅沿着纤维插入件的一个或多个侧边缘连接聚合物材料块体。所得的载体的可见表面可基本没有可造成载体局部削弱的源头的汇合线或其它瑕疵。
如上文所领会的，载体可具有(i)由第一聚合物材料块体限定的聚合物部分，(ii)由至少一种纤维插入件限定的局部补强部分，和(iii)聚合物部分和局部补强部分之间的界面部分，其中聚合物部分、界面部分和局部补强部分通常为连续的结构。界面部分可包括(i)由第一和第二聚合物材料限定的相互渗透网络，(ii)第一和第二聚合物材料之间的化学键，或(i)和(ii)二者。
可活化材料的一侧或多侧可为粘性的。虽然也可能一侧或多侧在室温下将对接触大致非粘性。一种或多种机械紧固件可通过附加至可活化材料、载体或二者，或者与可活化材料、载体或二者整合成形而使用。
可用于可活化材料的合适的材料包括可膨胀材料和不膨胀的材料。然而，考虑可活化材料可被活化来形成泡沫。例如，材料可活化来形成结构泡沫体(例如材料可包含环氧成分)。材料可活化来形成声学泡沫。材料可活化而流动，用于密封腔内区域的目的。材料可包括可活化而膨胀的材料和不可活化而膨胀的材料的组合。
本教导的结构补强可用来结构地补强制品，例如通过在制品的腔内定位结构补强，并活化可活化材料以便其膨胀并接合至制品表面。结构补强也可用于密封和/或隔挡腔。在优选的应用中，结构补强用于补强运输车辆，例如机动车。
通过实例的方式，结构补强可在涂布车辆之前布置在运输车辆(例如机动车)的腔内。当在涂装车间烤漆操作期间受热时，可活化材料可被活化。在可活化材料热活化的应用中，热膨胀材料，包含热活化材料的材料的选择和配方涉及的重要考虑是材料将发生反应或膨胀或可能地固化的温度。例如，在多数应用中，不期望材料在室温下或者在生产线环境的室温下是反应性的。更具体地，可活化材料在更高的处理温度下变为反应性的，例如在汽车装配厂遇到的温度下，当材料在升高的温度下或更高的施加能量的水平下与汽车组件一起处理时，例如在喷漆或电喷固化或烤漆步骤时。虽然汽车组装操作中遇到的温度可在约140℃至约220℃的范围内(例如约148.89℃至约204.44℃(约300°F.至400°F.))，车体和涂装车间应用通常为约93.33℃(约200°F.)或稍微更高。可活化材料的活化之后，材料通常将固化。由此，可能加热可活化材料，然后材料可膨胀，并由此固化而形成所得的泡沫材料。
如上所述，本文的教导也涉及可活化材料用的载体(例如用于制品用的结构补强)的制作方法。方法可包含将具有外表面并包括至少一种延长纤维排列的至少一种纤维插入件(其可在插入步骤时为固结的)插入工具的腔中。聚合物材料块体可成型为与纤维插入件接触，从而所得的聚合物材料的成型块体整体地连接纤维插入件(其固结为其最终状态)，并且纤维插入件的外表面与所得的聚合物材料块体的外表面至少部分共同延伸和连续。可活化材料的块体可选择性地施加(例如二次成型、机械附着或其它)在所得的聚合物材料块体或纤维插入件的外表面之一或二者的至少一部分上。与上文的教导一致，聚合物材料块体可通过外部刺激而活化以膨胀(例如，即使不完全，也至少部分地填充间隙或腔)并能固化以形成接合至其附着的制品的至少一个表面的粘合剂。
方法可包含将纤维插入件放置在工具的腔中后至少部分地定形纤维插入件的步骤。例如，在将纤维插入件放入工具的腔之前，工具可预热至高于至少一种纤维插入件的聚合物的软化温度和/或熔融温度的温度。方法可包括在纤维插入件放置在工具的腔中后和在成型聚合物材料块体时至少部分地定形纤维插入件的步骤。例如，将聚合物材料块体引入至腔中(例如通过注射成型)而产生的热和/或压力可至少部分地导致纤维插入件呈现由限定腔的一个或多个壁决定的形状。由此可能纤维插入件在放置于腔中前不预成形，并仅当处于腔中时呈现其最终形状。当然，也可能纤维插入件在放置于腔中前预成形。
纤维插入件，在插入步骤之前，可按一层或多层带和/或片的形式提供，其中纤维可固定于相互的位置(例如作为通过形成分布在连续的聚合基质中的纤维的粘性块体的固结的结果)。方法可由此包括制造纤维插入件以包含多个带和/或片的层的步骤。例如，方法包括当多个层受热并任选地受到增加的压力时固结带和/或片的多个层的步骤。例如，可使用高于带和/或片的聚合物的熔点和/或软化点的温度，以导致两个或更多个连接的层融合并在冷却时保持连接在一起。可使用约0.1至约1MPa的压力(例如约0.2至约0.6MPa)。温度和压力可施加期望量的时间，以基本获得完全的稠化。应理解本教导提供各种固结插入件结构的形成。
纤维插入件可热成形以形成预定的形状。纤维插入件可在固结步骤期间热成形。所得的热成形纤维插入件可此后放置在工具腔中并且可引入熔融的热塑性聚合物材料与之接触。
成型步骤可包括通过定位为与至少一种纤维插入件在通常相对关系的口的方式将熔融聚合物材料引入工具腔的步骤。在此方式中，当引入腔中时，熔融的聚合物在与接触限定腔的壁之前接触纤维插入件。
根据本教导制作的载体可具有具备第一表面和大致相反的第二表面的壁。壁的厚度可在约0.2至约6mm(例如约1.5至约4mm)的范围。在载体内选择的区域，可能壁厚度的至少约20％、40％、60％、80％或甚至100％由纤维插入件限定。纤维插入件可具有可见地暴露在载体上的轮廓外表面部分。纤维插入件可具有可见地暴露在载体上的大致平直的外表面部分。第一表面和第二表面可大致相互平行。
纤维插入件可占据全部载体的至少约10重量％、20重量％、30重量％或甚至40重量％。纤维插入件可小于全部载体的约90重量％、80重量％或甚至70重量％。
由此，可能第一表面和第二表面的至少一部分各自可见地暴露，并将由纤维插入件构成。载体将具有一种或多种附加的结构补强或其它结构特征，例如一个或多个肋、套筒(bosses)或其它。这些特征可没有或可包括根据本教导的纤维插入件。
本文的部分可用于任何多种目的。例如，它们可用于结构地补强例如机动车等运输车辆。在这方面，部件可放置在例如车辆框架等车体结构的腔中。向车体(例如在腔中)涂布电喷层后，部件可受到来自烤炉的热，其导致可活化材料活化(例如膨胀并填充腔)，并变为接合至车体。
图1-5说明根据本教导的实例。参照图1，可见具有第一聚合物材料的一种或多种块体12的载体10。显示纤维插入件14沿着插入件的边缘连接至一种或多种块体。描绘了界面部分16(为说明的目的而以夸张的形式；为了简化，从剩余图中省略此类界面，虽然应理解其仍在此类实施方案中存在)。载体具有上表面18和下表面20。纤维插入件14从上表面跨越至下表面，以便纤维插入件可视地暴露顶部和底部。图1省略了可活化材料。然而，可活化材料可处于块体12或纤维插入件14之一或二者上。
图2描绘了具有聚合物材料块体112和纤维插入件114的载体110，其中仅纤维插入件的上表面暴露。下表面和侧边缘连接聚合物材料块体。在此示意图中省略界面区域，虽然界面区域可能存在。在此图中，可膨胀材料126处于聚合物材料块体和纤维插入件二者上。然而，其也可处于之一或其它上。
图3说明具有具备上表面218的纤维补强部分214的载体210，由该上表面218伸出了由聚合物材料块体(例如，如插入件连接的载体中另外存在的相同类型的材料)制成的肋222。肋包括宽度为w1的向外伸出部分，和具有以例如至少约10％、20％或30％的量大于宽度w1的宽度w2(在其最大尺寸处)的放大的颈部区域。宽度w2可例如按不超过约100％、80％或60％的量大于宽度w1。类似的肋结构可用于图2的实施方案。
图4a和4b说明包含聚合物材料块体312和一对纤维插入件314的载体310的两个视图。在此情况下纤维插入件具有暴露的上下表面。不过也可使用如图2中仅上表面暴露的结构。使用多个肋322(肋以相对于纵轴横向的位置示出(然而对于本文的所有实施方案，肋可纵向、横向、斜向或其任意组合延伸；肋也可为弓形))。示出可活化材料326。虽然以沟槽示出，但对于本文的所有实施方案可倚靠在外表面上或者承载在载体上。
图5说明纤维插入件14、114、214或314可如何具有具备不同纤维取向的两个或更多个连接层的多个层的实例。虽然在此实例中示出为单向取向，浸渍纤维的条也可设置为纺织层。除了图5公开以外的其它取向也是可能的。例如三层单向取向的纤维可按相对于各自0/90/0度取向，或五层可按相对于各自0/45/90/45/0度取向。其它取向也是可能的。
图6a和6b说明根据本教导的一种部件的实例。部件包括示为成型部件的载体610。其包括纤维插入件614。载体包括多个肋622。可活化材料626施用在载体的部分上，并示为部分覆盖插入件614。二次成型以限定载体610的插入件614，包括弓形表面，并特别地包括凹面部分640。在示出的实施方案中，其定位为朝向插入件614的端部。插入件614也包括贯穿孔洞642。插入件包括一对对向壁644(其可大致平行或为其它取向)和横穿壁646。插入件跨越载体的中心部分。
图7a和7b说明根据本教导的另一部件的实例。部件包括示为成型部件的载体710。其包括纤维插入件714。载体包括多个肋722。可活化材料726施用在载体的部分上，并示为部分覆盖插入件714。二次成型以限定载体710的插入件714，包括弓形表面部分740。在示出的实施方案中，其定位为朝向插入件714的端部。插入件714也包括贯穿孔洞742。插入件包括一对对向壁744(其可大致平行或为其它取向)和横穿壁746。至少一个台阶748在插入件中限定。
图8图示出可如何根据本教导制作载体。纤维材料850的卷轴可供应材料来限定示为正弦形的插入件814。插入件可二次成型以限定所得载体810的二次成型部分852(例如，包括多个肋)。所得的载体由此包括插入件814和二次成型部分852。
图9A-9F为成型方法的图示，其中图9A示出纤维补强的载体3的片在图9B示出的加热器2中受热，然后放置在二组件模具4和5中，并通过向下按压模具4的上部来加压载体3以顺应于图9C示出的模具(5)的形状而定形。然后如图9D所示移走成形载体，并放置在注射模具6中，在此处如图9E所示与热塑性材料7首先二次成型。注射模具可打开以提供用于如图9F所示与粘合性材料8进一步二次成型的空间。
图10和11比较了具有玻璃纤维补强的聚酰胺的本发明产品与钢的性质。
将理解，即使图1至11的实施方案分别示出，一种方案的特征可与其它方案的特征组合，并保持在本教导的范围内。本文的记述由此应视为一般性的，并适用于本文作为整体的教导。
通用注释
本文的教导联系用于结构补强的载体而说明，其中载体大致延长(例如，其可为至少约25mm长，至少约50mm长或甚至至少约100mm长)。然而，教导不意图为如此限制性的。本教导也考虑用于形成隔挡和/或密封用的载体的用途。载体可由此具有小于约25mm(例如约15mm或更短)的长度。载体可比其宽度更长。载体可比其长度更宽。
如可从本文的教导理解的，可意识到多种益处和/或优点。例如，部件可制备为具有由无热固性塑料的材料制成的载体。部件可制备为具有处在本教导的纤维插入件上并与本教导的纤维插入件接触的至少一部分可活化材料。
如本文所使用的，除非另有声明，本教导预见种属(清单)的任意构件可能从种属中排除；和/或马库什组的任意构件可从组中排除。
除非另有声明，本文列举的任何数值包括从低值至高值以一单位为增量的所有值，前提是任意低值和任意高值之间有至少2单位的间隔。作为实例，如果声明组分的量、性质、或者例如温度、压力、和时间等的过程变量的值为例如1至90，优选20至80，更优选30至70，则意指例如(如15至85，22至68，43至51，30至32等)中间范围值在此说明书的教导范围内。类似地，单独的中间值也在本教导的范围内。对于小于1的值，一单位视为如合适的0.0001、0.001、0.01或0.1。这些仅是特别意图的实例，并且低值和高值之间数值的所有可能组合示为以类似的方式在本申请中明确声明。如可以看到的，本文中表达为“重量份”的量的教导也考虑以重量百分数表示的相同范围。由此，以“所得的组合物的至少‘x’重量份”为单位的范围内的表达也考虑所得的组合物的以重量百分比计的相同列举量"x"的范围的教导。
除非另有声明，所有范围包括两个端点和端点之间的所有数字。与范围联用的“约”或“大约”的使用适用于范围的两个端点。由此，“约20至30”意图覆盖“约20至约30”，包括至少指明的端点。
所有文章和参考文献的公开，包括专利申请和公开，通过引用并入用于任何目的。术语“基本由…组成”描述组合应包括鉴别的元素、成分、组件或步骤，以及此类不太影响组合的基本和新特征的其它元素、成分、组件或步骤。本文中用来描述元素、成分、组件或步骤的组合的术语“包含”或“包括”的使用也考虑由元素、成分、组件或步骤组成，或者由元素、成分、组件或步骤基本组成的实施方案。
复数的元素、成分、组件或步骤可通过单个整合的元素、成分、组件或步骤来提供。可选地，单个整合的元素、成分、组件或步骤可分解成分离的多个元素、成分、组件或步骤。用来描述元素、成分、组件或步骤的“一种(a)”或“一个(one)”的公开不意图排除附加的元素、成分、组件或步骤。
应理解上文的描述意图为解释性的而不是限制性的。除了实例(实施例)所提供的以外，很多实施方案和很多应用将在阅读上文的说明时对本领域技术人员变得明显。因此本发明的范围不应参照上文的说明而确定，而应当参照所附的权利要求，与权利要求授予的等价方案的全部范围一起来确定。所有文章和参考文献的公开，包括专利申请和公开，通过引用并入用于所有目的。本文公开的主题的任何方面在下面的权利要求中的省略不是此主题的放弃声明，也不应视为发明人不考虑此主题作为公开的发明主题的部分。

Claims (60)

1.一种用于制品的结构补强、隔挡和/或密封的装置，其包括：
a.载体，所述载体包括：
i.具有外表面并包括第一聚合物材料的聚合物材料块体；和
ii.至少一种固结纤维插入件，所述固结纤维插入件具有外表面、并包括至少一种具有以预定方式分布在第二聚合物材料中的多个有序纤维的延长纤维排列，所述纤维插入件在预定位置连接所述聚合物材料块体、用于承载在所述预定位置处受到的预定负荷；其中所述纤维插入件和所述聚合物材料块体包括相容的材料、结构、或材料与结构二者，用于使所述纤维插入件至少部分连接至所述聚合物材料块体；和
b.选择性地施用在所述聚合物材料块体的一个或两个外表面的至少一部分、或选择性地施用在至少一种纤维插入件上的可活化材料块体，所述可活化材料块体可通过外部刺激而活化以膨胀，并可固化以形成接合至所述制品的至少一个表面的粘合剂；其中所述纤维插入件的所述外表面与所述聚合物材料块体的所述外表面至少部分地共同延伸和连续。
2.根据权利要求1所述的装置，其中所述聚合物材料块体包括热塑性材料。
3.根据权利要求1或2所述的装置，其中所述至少一种固结纤维插入件包括通常由与所述聚合物材料块体相同类型的材料制成的带材料形式的至少一层。
4.根据权利要求1至3任一项所述的装置，其中所述至少一种固结纤维插入件的至少一种延长纤维排列包括通常由与所述聚合物材料块体相同类型的材料制成的材料。
5.根据权利要求1至4任一项所述的装置，其中所述至少一种固结纤维插入件的至少一种延长纤维排列包括通常由与所述聚合物材料块体相同类型的材料制成的材料，使得所述纤维插入件的材料和所述聚合物材料块体化学地融合在一起。
6.根据权利要求1至5任一项所述的装置，其中所述至少一种延长纤维排列为纺织纤维排列。
7.根据权利要求1至6任一项所述的装置，其中所述至少一种延长纤维排列是用与所述聚合物材料块体的材料通常相同类型的材料浸渍的纺织纤维排列。
8.根据权利要求1至7任一项所述的装置，其中所述至少一种延长纤维排列是由与所述聚合物材料块体通常相同类型的材料制成的纺织纤维排列，并用与所述聚合物材料块体的材料通常相同类型的材料浸渍。
9.根据权利要求1至8任一项所述的装置，其中聚酰胺材料用作所述聚合物材料块体、或者所述纤维插入件的至少一部分的一种或多种。
10.根据权利要求1至9任一项所述的装置，其中所述纤维插入件包括各自包括延长纤维排列的多个层，和各层在其机械性质上为各向异性。
11.根据权利要求1至10任一项所述的装置，其中所述纤维插入件包括包含玻璃纤维、矿物纤维、碳纤维、聚合物纤维或其任意组合的多种纤维。
12.根据权利要求1至11任一项所述的装置，其中所述可活化材料块体包括环氧系材料。
13.根据权利要求1至12任一项所述的装置，其中将所述延长纤维排列中一个或多个纤维的取向选择为响应于施加于所述延长纤维排列的预定负荷提供局部刚性。
14.根据权利要求1至13任一项所述的装置，其中所述纤维插入件的所述外表面与所述聚合物材料块体的所述外表面通常共同延伸。
15.根据权利要求1至14任一项所述的装置，其中所述载体的所得外表面基本没有可造成所述载体局部削弱源头的汇合线或其它瑕疵。
16.根据权利要求1至15任一项所述的装置，其中所述至少一种固结纤维插入件具有暴露的外表面和暴露的内表面。
17.根据权利要求1至16任一项所述的装置，其中所述载体具有(i)由所述聚合物材料块体限定的聚合物部分，(ii)由所述至少一种固结纤维插入件限定的局部补强部分，和(iii)所述聚合物部分和所述局部补强部分之间的界面部分，其中所述聚合物部分、所述界面部分和所述局部补强部分通常为平滑和/或连续的结构。
18.根据权利要求17所述的装置，其中所述界面部分包括(i)由所述第一和第二聚合物材料限定的互穿网络，(ii)所述第一和第二聚合物材料之间的化学键，或者(i)和(ii)二者。
19.根据权利要求1至18任一项所述的装置，其中所得载体展现(i)没有对裸眼可见的汇合线，(ii)没有跨越所述界面部分的对裸眼可见的空隙或间断，或者(i)和(ii)二者。
20.根据权利要求1至19任一项所述的装置，其中所述制品为运输车辆。
21.一种方法，其用于制作制品的结构补强、隔挡和/或密封用的装置，所述方法包括：
a.将具有外表面并包括至少一种延长纤维排列的至少一种固结纤维插入件插入工具的腔；
b.将与所述纤维插入件接触的聚合物材料块体成型，使所得的成型聚合物材料块体整体地连接所述纤维插入件，且所述纤维插入件的所述外表面与所得的成型聚合物材料块体的外表面至少部分地共同延伸和连续；和
c.将可活化材料块体选择性地施用在所得的聚合物材料块体或所述纤维插入件的一个或两个外表面的至少一部分上，所述可活化材料块体可通过外部刺激而活化以膨胀，并可固化以形成接合至所述制品的至少一个表面的粘合剂。
22.根据权利要求21所述的方法，其中所述方法包括在将至少一种固结纤维插入件放置在所述工具的腔中之后，至少部分地定形所述至少一种固结纤维插入件的步骤。
23.根据权利要求21或22所述的方法，其中在将所述纤维插入件放置在所述工具的所述腔之前，将所述工具预热至比所述至少一种固结纤维插入件的聚合物的软化温度和/或熔融温度高的温度；和/或在放置于腔中之前所述纤维插入件不预成形。
24.根据权利要求21至23任一项所述的方法，其中所述方法包括在将所述至少一种固结纤维插入件放置在所述工具的腔中之后和当成型所述聚合物材料块体时，至少部分地定形所述至少一种固结纤维插入件的步骤。
25.根据权利要求21至24任一项所述的方法，其中在插入步骤之前以带或片的形式提供所述至少一种固结纤维插入件。
26.根据权利要求21至25任一项所述的方法，其中所述方法包括制造所述至少一种固结纤维插入件以包括带或片的多个层的步骤。
27.根据权利要求21至25任一项所述的方法，其中所述方法包括在热和压力下固结带或片的多个层的步骤。
28.根据权利要求26或27所述的方法，其中将带或片的各连接的层取向为具有相对于连接层的纤维以不同的预定方向排布的纤维。
29.根据权利要求21至28任一项所述的方法，其中成型步骤包括通过定位为与所述至少一种固结纤维插入件通常为相对关系的口的方式将所述聚合物材料引入所述腔中。
30.一种装置，其包含用于形成纤维补强热塑性片的纤维插入件，由此所述热塑性片接合至聚合物材料块体，和所述装置进一步包括可活化材料。
31.根据权利要求30所述的装置，其中所述可活化材料为可发泡和/或粘合性材料。
32.根据权利要求30或权利要求31所述的装置，其中所述聚合物材料块体提供从所述纤维补强热塑性片的一侧或双侧延伸的补强肋。
33.根据权利要求30至32任一项所述的装置，其中所述聚合物材料块体包含短纤维填充的聚酰胺。
34.根据权利要求30至33任一项所述的装置，其中所述可活化材料设置在所述纤维补强热塑性片和/或所述聚合物材料块体的选择的表面上。
35.根据权利要求30至34任一项所述的装置，其中所述可活化材料为热活化热固性树脂。
36.根据权利要求35所述的装置，其中所述热活化热固性树脂为环氧树脂。
37.一种制造装置的方法，所述方法包括将纤维补强热塑性片热成形，向所述热成形片提供聚合物材料块体，并进一步向所述热成形热塑性片和/或所述聚合物材料块体的表面提供可活化材料。
38.根据权利要求37所述的方法，其中所述聚合物材料块体通过将所述热成形片放置在模具中并将所述聚合物材料块体注射在所述热成形片上而提供。
39.根据权利要求37所述的方法，其中所述可活化材料通过挤出或注射成型在所述纤维补强热塑性片和所述聚合物材料块体上而提供。
40.根据权利要求37至39任一项所述的方法，其中所述可活化材料为粘合性和/或可发泡材料。
41.根据权利要求37至40任一项所述的方法，其中所述聚合物材料块体为短纤维填充的聚酰胺。
42.根据权利要求37至41任一项所述的方法，其中所述可活化材料为热活化可发泡热固性树脂。
43.根据权利要求42所述的方法，其中所述可活化材料含有热活化固化剂。
44.一种组件，其包含接合至附加强化材料的成形连续纤维补强热塑性片，并进一步含有热活化材料。
45.根据权利要求44所述的组件，其中所述热活化材料为可发泡和/或粘合性材料。
46.根据权利要求44或权利要求45所述的组件，其中所述附加强化材料提供从所述成形连续纤维补强热塑性片的一侧或双侧延伸的补强肋。
47.根据权利要求44至46任一项所述的组件，其中所述附加强化材料包含短纤维填充的聚酰胺。
48.根据权利要求44至47任一项所述的组件，其中所述热活化材料设置在所述连续纤维补强热塑性片和/或所述附加强化材料的选择的表面上。
49.根据权利要求44至47任一项所述的组件，其中所述可活化材料为热活化热固性树脂。
50.根据权利要求49所述的组件，其中所述热活化热固性树脂为环氧树脂。
51.一种制造组件的方法，所述方法包括将连续纤维补强热塑性片热成形，向所述热成形片提供附加强化材料，并进一步向所述热成形热塑性片和/或所述附加强化材料的表面提供热可活化材料。
52.根据权利要求51所述的方法，其中所述附加强化材料通过将所述热成形片放置在模具中并将所述附加强化材料注射至所述热成形片上而提供。
53.根据权利要求52所述的方法，其中所述可活化材料通过挤出或注射成型至所述热成形片和所述附加强化材料的双组件材料上而提供。
54.根据权利要求51至53任一项所述的方法，其中所述可活化材料为粘合性和/或可发泡材料。
55.根据权利要求51至54任一项所述的方法，其中所述附加强化材料为短纤维填充的聚酰胺。
56.根据权利要求51至权利要求55任一项所述的方法，其中所述可活化材料为热活化可发泡热固性树脂。
57.根据权利要求56所述的方法，其中所述可发泡热固性树脂含有热活化固化剂。
58.一种在腔中提供补强的方法，所述方法包括将根据权利要求44至50任一项所述的组件放置在腔中，并加热以活化所述可活化材料。
59.根据权利要求58所述的方法，其中所述腔为车体壳中的腔，和所述加热在140℃至220℃的温度下进行。
60.根据权利要求44至50任一项所述的组件在生产机动车工业或航空航天工业用的组件中的用途。
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US11959224B2 (en) 2024-04-16
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US20230002965A1 (en) 2023-01-05

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