GB2342889A - Coating glass mat thermoplastics - Google Patents

Coating glass mat thermoplastics Download PDF

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Publication number
GB2342889A
GB2342889A GB9823129A GB9823129A GB2342889A GB 2342889 A GB2342889 A GB 2342889A GB 9823129 A GB9823129 A GB 9823129A GB 9823129 A GB9823129 A GB 9823129A GB 2342889 A GB2342889 A GB 2342889A
Authority
GB
United Kingdom
Prior art keywords
glass mat
mould
mat thermoplastic
thermoplastic
coating
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.)
Withdrawn
Application number
GB9823129A
Other versions
GB9823129D0 (en
Inventor
Mark Wilson Pharaoh
Robert John Coates
Paul David Stidworthy
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.)
MG Rover Group Ltd
Original Assignee
MG Rover Group Ltd
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 MG Rover Group Ltd filed Critical MG Rover Group Ltd
Priority to GB9823129A priority Critical patent/GB2342889A/en
Publication of GB9823129D0 publication Critical patent/GB9823129D0/en
Publication of GB2342889A publication Critical patent/GB2342889A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
    • B29C70/345—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using matched moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00—Layered products having a general shape other than plane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/34—Layered products comprising a layer of synthetic resin comprising polyamides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/04—Polyethylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2379/00—Other polymers having nitrogen, with or without oxygen or carbon only, in the main chain
    • B32B2379/08—Polyimides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B32B2605/08—Cars

Abstract

A compression moulded glass mat thermoplastic (GMT) product has a coating layer and an interlayer of melt viscosity suitable to absorb the shrinkage stress of the GMT. Uneven surface finish due to such shrinkage is thus avoided, and the surface finish may be of Class A automotive type. The product may be made by moulding a sheet 12, comprising a coating layer 14 of nylon, polyester or polyvinylfluoride on a backing interlayer 16 of random ethylene/polypropylene copolymer, on to a blank 10 of glass fibre filled polypropylene.

Description

A Polymer Coating System The present invention relates to an improved polymer coating system. The invention has particular, but not exclusive, use in the automotive industry.
A known construction of an automotive bumper having a support, a core and a shell comprises a foamed polyurethane core, a support of a glass fibre reinforced polyester resin sheet moulding compound and a shell of a propylene polymer modifie with an ethylene/propylene rubber and a coating material such as polyurethane.
However, this does not produce a high quality surface finish, the automotive Class A finish. The surface finish of compression moulded glass mat thermoplastic (GMT) components is generally quite poor. A GMT typically comprises a glass fibre filled polypropylene. During cooling, the polypropylene shrinks relative to its molten state. The end result is that the glass fibres are left proud of the surface of the polypropylene creating an uneven and hence undesirable surface finish. To overcome this problem it is known, in the example given above, to modify the rubber containing propylene polymer by the addition of additives such as talc, chalk and the like to improve coating adhesion and properties such as heat resistance and shrinkage.
It is an advantage of the present invention that it provides for an improved surface finish of a moulded glass mat thermoplastic than has previously been possible. Conveniently, the surface finish is of the Class A automotive type.
According to a first aspect of the present invention a coated glass mat thermoplastic comprises a glass mat thermoplastic, an interlayer and a coating layer characterised in that the interlayer has a melt viscosity suitable to absorb the shrinkage stresses of the glass mat thermoplastic.
Preferably, the interlayer comprises a layer of a random ethylene/polypropylene copolymer.
According to a second aspect of the present invention, a method of coating a glass mat thermoplastic comprises the steps of providing an open compression mould, the mould comprising a cavity defined by a first mould surface and a second mould surface, providing a body of a glass mat thermoplastic on the first mould surface, providing a coating sheet with a backing layer having a melt viscosity suitable to absorb the shrinkage stresses of the glass mat thermoplastic, placing the sheet on the body with the backing layer adjacent the body, and closing the mould to apply pressure to the blank causing the materials within the mould to deform, fill the cavity and solidify on cooling and then opening the mould to remove a coated glass mat plastics component.
The invention has the advantage that the low melt interlayer masks the differential shrinkage such that a good surface finish is obtained on the coated component. The surface finish of the component is determined by the surface finish of the second mould surface. In particular, a Class A automotive finish can be obtained by the use of a suitably smooth mould surface, for example a chromed mould surface.
Preferably, the interlayer comprises a random ethylene/polypropylene copolymer.
Preferably the coating layer comprises a nylon, a polyester or a polyvinyldifluoride (PVDF).
The invention will now be described, by way of example only, with reference to the accompanying drawings, in which Figure 1 shows in diagrammatic form a section through an apparatus in a first step of the method of the present invention ; Figure 2 shows in diagrammatic form a section through the apparatus of Figure 1 in a further step of the method of the present invention; and Figure 3 shows in diagrammatic form a section through the apparatus of Figure 1 in a final step of the method of the present invention.
The invention will now be described with reference to Figures 1 to 3. A mould assembly 1 is shown comprising a first mould platen 2 and a second mould platen 3. The first mould platen 2 includes a first mould surface 4 and the second mould platen 3 inclues a second mould surface 5 complimentary to the first mould surface 4 on the first mould platen 2. The first and second mould surfaces, when brought together define a cavity 8.
A plurality of sheets of a glass mat thermoplastic may be placed onto the second mould surface 5 of the second mould platen 3 to form a blank 10 of glass mat thermoplastic material.
A single sheet is shown in the drawings for reasons of clarity. The glass mat thermoplastic sheets 10 comprises a glass fibre filled thermoplastic material, in which the thermoplastic material is typically a polypropylene. The sheets may be preheated prior to location on the platen. The sheets may typically be heated to about 200 C. Preheating expands the glass mat thermoplastic sheets and places the thermoplastic material in a condition that it might more easily flow to the shape desired.
A sheet 12 comprising a coating layer 14 of a nylon, a polyester or a polyvinyldifluoride (PVDF) is provided with a backing layer 16 having a melt viscosity suitable to absorb the shrinkage stresses of the glass mat thermoplastic. Preferably, the backing layer 16 comprises a random ethylene/polypropylene copolymer. Such a sheet 12 comprising a coating layer of polyvinyldifluoride is commercially available from Rexam. The sheet 12 is placed on the blank 10 of glass mat thermoplastics material with the backing layer 16 adjacent the blank.
The first mould platen 2 is then brought down into contact with the second mould platen 3 to form the cavity 8. The platens 2,3 close the cavity about its edges to prevent the thermoplastics material from flowing out of the cavity 8. The platens 2,3 may be heated to about 100 C. This ensures that the thermoplastics material has an opportunity to flow to fill the cavity behind the sheet 12 prior to solidification of the thermoplastics material on cooling.
During cooling, the thermoplastics material begins to shrink relative to its molten state.
A surface of the interlayer of random ethylene/propylene copolymer adjacent the thermoplastics material, due to the heat of the thermoplastics material, becomes at least partially able to flow to fill up the gaps formed by shrinkage. Further, the low melt interlayer retains a melt condition while the glass mat thermoplastic shrinks. In other words, the low melt interlayer is the last to solidify and in this way the shrinkage stresses generated by the glass mat thermoplastic are accommodated by the low melt interlayer. The coating layer adjacent the mould is able to retain its integrity and its smooth surface to provide a smooth surface finish on the final moulded component.
The mould assembly is then opened to allow for the removal of the moulded component 18. The finished component 18 has a surface finish on a front side 20 corresponding to the surface finish of the first mould surface 4. In this way, a Class A automotive surface finish may be obtained on the front side 20 of the component 18.
The second mould surface 5 does not need to be of any particular surface quality if a rear surface 22 of the component is to be hidden from view.

Claims (8)

1. A coated glass mat thermoplastic comprising a glass mat thermoplastic, an interlayer and a coating layer characterised in that the interlayer has a melt viscosity suitable to absorb the shrinkage stresses of the glass mat thermoplastic.
2. A coated glass mat thermoplastic according to claim 1, characterised in that the intermediate layer comprises a random ethylene/polypropylene copolymer.
3. A coated glass mat thermoplastic according to claim 1 or claim 2, characterised in that the coating layer comprises a nylon, a polyester or a polyvinyldifluoride (PVDF).
4. A coated glass mat thermoplastic substantially as described herein with reference to and as illustrated in the accompanying drawings.
5. A method of coating a glass mat thermoplastic comprises the steps of providing an open compression mould, the mould comprising a cavity defined by a first mould surface and a second mould surface, providing a body of a glass mat thermoplastic on the first mould surface, providing a coating sheet comprising a coating layer and a backing layer having a melt viscosity suitable to absorb the shrinkage stresses of the glass mat thermoplastic, placing the sheet on the body with the backing layer adjacent the body, and closing the mould to apply pressure to the blank causing the materials within the mould to deform, fill the cavity and solidify on cooling and then opening the mould to remove a coated glass mat plastics component.
6. A method according to claim 5, characterised in that the intermediate layer comprises a random ethylene/polypropylene copolymer.
7. A method according to claim 5 or claim 6, characterised in that the coating layer comprises a nylon, a polyester or a polyvinyldifluoride (PVDF).
8. A method of coating a glass mat thermoplastic substantially as described herein with reference to and as illustrated in the accompanying drawings
GB9823129A 1998-10-23 1998-10-23 Coating glass mat thermoplastics Withdrawn GB2342889A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9823129A GB2342889A (en) 1998-10-23 1998-10-23 Coating glass mat thermoplastics

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9823129A GB2342889A (en) 1998-10-23 1998-10-23 Coating glass mat thermoplastics

Publications (2)

Publication Number Publication Date
GB9823129D0 GB9823129D0 (en) 1998-12-16
GB2342889A true GB2342889A (en) 2000-04-26

Family

ID=10841092

Family Applications (1)

Application Number Title Priority Date Filing Date
GB9823129A Withdrawn GB2342889A (en) 1998-10-23 1998-10-23 Coating glass mat thermoplastics

Country Status (1)

Country Link
GB (1) GB2342889A (en)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1211054A1 (en) * 2000-12-01 2002-06-05 Bayerische Motoren Werke Aktiengesellschaft Process for the production of a fiber reinforced composite structure
DE102006049913A1 (en) * 2006-10-18 2008-04-24 Schmuhl Faserverbundtechnik Gmbh & Co. Kg Surface finished shaped articles, e.g. automobile bodywork components, have elastic intermediate layer between thermoplastic film and plastics support to ensure smooth surface
WO2015013692A1 (en) * 2013-07-26 2015-01-29 Magna International Inc. Mould arrangement and method for compression moulding fiber reinforced preforms

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112454708A (en) * 2020-10-22 2021-03-09 上海名辰模塑科技有限公司 Preparation method of automobile bumper composite material

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4153490A (en) * 1977-05-05 1979-05-08 Werzalit, J. F. Werz Jr. Kg Pressholzwerk Method of manufacturing coated composite articles from a non-flowable mixture, and articles obtained thereby
US4716072A (en) * 1986-12-29 1987-12-29 General Electric Company Multilayer composite structure for smooth surfaces
US4956224A (en) * 1985-11-05 1990-09-11 Societe Chimique Des Charbonnages S.A. Articles produced from a laminate and process for their manufacture

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4153490A (en) * 1977-05-05 1979-05-08 Werzalit, J. F. Werz Jr. Kg Pressholzwerk Method of manufacturing coated composite articles from a non-flowable mixture, and articles obtained thereby
US4956224A (en) * 1985-11-05 1990-09-11 Societe Chimique Des Charbonnages S.A. Articles produced from a laminate and process for their manufacture
US4716072A (en) * 1986-12-29 1987-12-29 General Electric Company Multilayer composite structure for smooth surfaces

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1211054A1 (en) * 2000-12-01 2002-06-05 Bayerische Motoren Werke Aktiengesellschaft Process for the production of a fiber reinforced composite structure
DE102006049913A1 (en) * 2006-10-18 2008-04-24 Schmuhl Faserverbundtechnik Gmbh & Co. Kg Surface finished shaped articles, e.g. automobile bodywork components, have elastic intermediate layer between thermoplastic film and plastics support to ensure smooth surface
WO2015013692A1 (en) * 2013-07-26 2015-01-29 Magna International Inc. Mould arrangement and method for compression moulding fiber reinforced preforms
US10814565B2 (en) 2013-07-26 2020-10-27 Magna International Inc. Mould arrangement and method for compression moulding fiber reinforced preforms

Also Published As

Publication number Publication date
GB9823129D0 (en) 1998-12-16

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