GB2349600A - Composite component - Google Patents

Composite component Download PDF

Info

Publication number
GB2349600A
GB2349600A GB9910351A GB9910351A GB2349600A GB 2349600 A GB2349600 A GB 2349600A GB 9910351 A GB9910351 A GB 9910351A GB 9910351 A GB9910351 A GB 9910351A GB 2349600 A GB2349600 A GB 2349600A
Authority
GB
United Kingdom
Prior art keywords
biodegradable
fibres
mould
layer
thermoplastic
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.)
Granted
Application number
GB9910351A
Other versions
GB9910351D0 (en
GB2349600B (en
Inventor
Kevin Albert Lindsey
Nicholas Tucker
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 GB9910351A priority Critical patent/GB2349600B/en
Publication of GB9910351D0 publication Critical patent/GB9910351D0/en
Publication of GB2349600A publication Critical patent/GB2349600A/en
Application granted granted Critical
Publication of GB2349600B publication Critical patent/GB2349600B/en
Anticipated expiration legal-status Critical
Expired - Fee Related 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
    • 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
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • 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
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/024—Woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
    • B29K2995/0037—Other properties
    • B29K2995/0059—Degradable
    • 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
    • B32B2262/06—Vegetal fibres
    • B32B2262/062—Cellulose fibres, e.g. cotton
    • B32B2262/065—Lignocellulosic fibres, e.g. jute, sisal, hemp, flax, bamboo
    • 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
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/716—Degradable
    • B32B2307/7163—Biodegradable

Abstract

A biodegradable composite 1 comprises a first layer 2 of biodegradable fibres, a second layer 4 of biodegradable fibres and a layer of biodegradable thermoplastic 6 disposed between the first and second layers of biodegradable fibres. The biodegradable thermoplastic permeates through each of the layers of biodegradable fibres. A method of manufacture of the composite is also disclosed (figure 2).

Description

Composite Component The present invention relates to a biodegradable composite component and to a method of manufacture of such a composite component. Such a composite component has particular, but not exclusive, utility in the automotive field.
There are growing commercial pressures to develop products from renewable resources, such as agricultural crops, which are also biodegradable. Such products have the advantage that their disposal is less environmentally unfriendly than that of non-biodegradable products.
A number of biodegradable composites are known. It is known, for example from DE 4 440 246, to mix cellulosic reinforcing fibres with a biodegradable thermoplastic matrix to form a biodegradable composite. The mixture is typically heated and subsequently injected or extruded into an injection moulding machine to form a composite component.
It is also known, for example from US 5 719 203, to mix caoutchouc, starch, cellulose and a biodegradable agent to form a plasticised mass which may be heated in a twin screw extruder and subsequently injected into an injection moulding machine to form a composite component.
In both cases the composite component produced relies upon effective mixing of the matrix and filler constituents occurring prior to moulding of the composite component.
According to a first aspect of the present invention, a biodegradable composite comprises a first layer of biodegradable fibres, a second layer of biodegradable fibres and a layer of biodegradable thermoplastic disposed between the first and second layers of biodegradable fibres, the biodegradable thermoplastic permeating through each of the first and second layers of biodegradable fibres to a surface of the composite component.
Preferably, the biodegradable thermoplastic includes biodegradable filler material such as miscanthus fibres.
Preferably, either or both of the first and second layers of biodegradable fibres comprise one or more sheets of woven or non woven fibres. More preferably, the first and second layers contain equal numbers of sheets of woven or non woven fibres.
Preferably, the biodegradable fibres comprise hemp, jute, or the like.
According to a second aspect of the present invention, a method of producing a composite component according to the first aspect of the invention, comprises the steps of : providing a first part of a mould; providing a second part of the mould, the first and second parts of the mould together defining a mould cavity having a surface; laying up a first layer of biodegradable fibres in the first part of the mould; introducing a quantity of the biodegradable thermoplastic to the first part of the mould over an uppermost surface of the first layer of biodegradable fibres; laying up a second layer of biodegradable fibres over the biodegradable thermoplastic; bringing the first and second mould parts together to compress the fibres and the biodegradable thermoplastic together such that the biodegradable thermoplastic permeates through the first and second layers of biodegradable fibres to the surface of the mould cavity.
Preferably, the quantity of the biodegradable thermoplastic is introduced to the mould by an extrusion apparatus.
The invention will now be described, by way of example only, with reference to the accompanying Figures, in which: Figure 1 shows a section through a composite material according to the present invention; Figure 2 shows a diagrammatic side section of an apparatus suitable for use in the manufacture of the present invention.
Referring first to Figure 1 there is shown a section through a composite component 1 in accordance with the present invention. A first layer 2 of biodegradable fibres is disposed towards an upper surface 3 of the composite component. A second layer 4 of biodegradable fibres is disposed towards a lower surface 5 of the composite component.
The first and second layers 2,4 are typically of equal thickness. The first and second layers 2,4 typically comprise similar biodegradable fibres. For preference, the fibres comprise cellulosic fibres from an agricultural crop such as jute or hemp. Alternatively, the fibres may be formed from a biodegradable plastic, preferably a biodegradable thermoplastic.
A layer 6 of biodegradable thermoplastic 7 is disposed between the first and second layers 2,4 of biodegradable fibres. The biodegradable thermoplastic permeates through each of the first and second layers of biodegradable fibres to the surfaces of the composite component.
The biodegradable thermoplastic may include a cellulosic filler material 8. This may again be obtained from an agricultural crop. A suitable filler material is miscanthus fibres.
A method of manufacture of such a composite will now be described with reference to Figure 2.
A mould apparatus 10 is shown having a first mould part 11 and a second mould part 12. The first mould part 11 defines a first part of a mould cavity. The second mould part 12 defines a second part of the mould cavity. The mould cavity has an inner surface 14 defined by the parts of the mould cavity. The first and second mould parts may be displaced relative to one another to open and close the mould cavity as indicated by arrow A.
An extruder 16 is provided to heat a biodegradable thermoplastic and subsequently extrude a quantity of the heated biodegradable thermoplastic. The extruder may be moveable as indicated by arrow B between a first position clear of the mould, and a second position in which it may extrude the heated biodegradable thermoplastic. Alternatively, an injector may be used for the same purpose.
While the first and second mould parts are separated from one another, a first layer 4 of biodegradable fibres is laid up in the first mould part. The first layer of fibres may comprise one or more separate sheets of woven or non woven fibres. For the purposes of clarity, the first layer in the illustrated embodiment of Figure 2 is shown comprising only a single sheet of fibres.
Once the first layer of fibres has been laid up, the extruder is moved from the first position to the second position. The extruder 16 then extrudes the quantity of biodegradable thermoplastic 7 onto an uppermost surface of the first layer 4 of fibres. The extruder is then returned to the first position. Before the thermoplastic 7 is allowed to cool, a second layer 2 of fibres is laid up over the biodegradable thermoplastic. As with the first layer of fibres, the second layer may comprise one or more separate sheets of woven or non woven fibres.
Again, for the purposes of clarity, the second layer in the illustrated embodiment of Figure 2 is shown comprising only a single sheet of fibres.
The first and second mould parts 11, 12 are then brought together to close the mould cavity and to compress the layers 2,4 of fibres and the biodegradable thermoplastic 7 together. This has the effect of forcing the biodegradable thermoplastic to permeate through the first and second layers of biodegradable fibres to the surface 14 of the mould cavity to form a surface of the composite component so formed. The thermoplastic 7 is allowed to cool before the mould cavity is opened and the formed composite component removed from the mould. In this way, the surface finish of the formed composite component is determined by the finish of the surface of the mould cavity.
In the illustrated embodiment of the invention, the first and second layers of biodegradable fibres contain equal numbers of similar sheets of woven or non woven fibres of substantially equal thickness. This has been found not to produce undesirable stresses on the upper and lower surfaces of the formed composite component which may lead to undesired twisting or curving of the formed composite component.

Claims (10)

1. A biodegradable composite component comprising a first layer of biodegradable fibres, a second layer of biodegradable fibres and a layer of biodegradable thermoplastic disposed between the first and second layers of biodegradable fibres, the biodegradable thermoplastic permeating through each of the first and second layers of biodegradable fibres to a surface of the composite.
2. A composite according to claim 1, characterised in that the biodegradable thermoplastic includes a biodegradable filler material such as miscanthus fibres.
3. A composite according to claim 1 or claim 2, characterised in that either or both of the first and second layers of biodegradable fibres comprise one or more sheets of woven or non woven fibres.
4. A composite according to claim 3, characterised in that the first and second layers contain equal numbers of sheets of woven or non woven fibres.
5. A composite according to any previous claim, characterised in that the biodegradable fibres comprise hemp, jute, or the like.
6. A composite according to any of claims 1 to 4, characterised in that the biodegradable fibres comprise a biodegradable plastic.
7. A biodegradable composite component substantially as described herein with reference to and as illustrated in Figure 1 of the accompanying drawings.
8. A method of producing a composite component according to any previous claim, comprises the steps of : providing a first part of a mould ; providing a second part of the mould, the first and second parts of the mould together defining a mould cavity having a surface; laying up a first layer of biodegradable fibres in the first part of the mould; introducing a quantity of the biodegradable thermoplastic to the first part of the mould over an uppermost surface of the first layer of biodegradable fibres; laying up a second layer of biodegradable fibres over the biodegradable thermoplastic; bringing the first and second mould parts together to compress the fibres and the biodegradable thermoplastic together such that the biodegradable thermoplastic permeates the layers of biodegradable fibres to the surface of the mould cavity.
9. A method according to claim 8, characterised in that the quantity of the biodegradable thermoplastic is introduced to the mould by an extrusion apparatus.
10. A method of producing a composite component substantially as described herein with reference to and as illustrated in Figure 2 of the accompanying drawings.
GB9910351A 1999-05-06 1999-05-06 A method of producing a biodegradable composite component Expired - Fee Related GB2349600B (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB9910351A GB2349600B (en) 1999-05-06 1999-05-06 A method of producing a biodegradable composite component

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB9910351A GB2349600B (en) 1999-05-06 1999-05-06 A method of producing a biodegradable composite component

Publications (3)

Publication Number Publication Date
GB9910351D0 GB9910351D0 (en) 1999-06-30
GB2349600A true GB2349600A (en) 2000-11-08
GB2349600B GB2349600B (en) 2003-12-10

Family

ID=10852826

Family Applications (1)

Application Number Title Priority Date Filing Date
GB9910351A Expired - Fee Related GB2349600B (en) 1999-05-06 1999-05-06 A method of producing a biodegradable composite component

Country Status (1)

Country Link
GB (1) GB2349600B (en)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2387139A (en) * 2002-02-28 2003-10-08 Lear Corp Manufacturing a composite panel
EP1661937A1 (en) 2004-11-25 2006-05-31 Frenzel GmbH Biodegradable container, especially a burial urn or an ash capsule, as well as pre-fabricated material for and method of producing said container
WO2011056293A1 (en) * 2009-11-06 2011-05-12 The Boeing Company Compression molding method and reinforced thermoplastic parts molded thereby
US9238339B2 (en) 2013-02-21 2016-01-19 The Boeing Company Hybrid fastener and method of making the same
US9283706B2 (en) 2013-12-03 2016-03-15 The Boeing Company Method and apparatus for compression molding fiber reinforced thermoplastic parts
US9302434B2 (en) 2013-12-03 2016-04-05 The Boeing Company Thermoplastic composite support structures with integral fittings and method
US9623612B2 (en) 2013-02-21 2017-04-18 The Boeing Company Method for fabricating composite fasteners

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0224064A2 (en) * 1985-11-29 1987-06-03 Dornier Gmbh Method for producing construction elements from fibre-reinforced thermoplastic material
US5783504A (en) * 1995-04-26 1998-07-21 Fiberweb Nonwoven/film biodegradable composite structure
EP0908303A2 (en) * 1997-10-08 1999-04-14 Prince Corporation Vehicle interior panel and method of manufacture

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0224064A2 (en) * 1985-11-29 1987-06-03 Dornier Gmbh Method for producing construction elements from fibre-reinforced thermoplastic material
US5783504A (en) * 1995-04-26 1998-07-21 Fiberweb Nonwoven/film biodegradable composite structure
EP0908303A2 (en) * 1997-10-08 1999-04-14 Prince Corporation Vehicle interior panel and method of manufacture

Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2387139A (en) * 2002-02-28 2003-10-08 Lear Corp Manufacturing a composite panel
GB2387139B (en) * 2002-02-28 2004-10-13 Lear Corp Method of manufacturing a composite panel
EP1661937A1 (en) 2004-11-25 2006-05-31 Frenzel GmbH Biodegradable container, especially a burial urn or an ash capsule, as well as pre-fabricated material for and method of producing said container
US9205579B2 (en) 2009-11-06 2015-12-08 The Boeing Company Compression molding method and reinforced thermoplastic parts molded thereby
US8709319B2 (en) 2009-11-06 2014-04-29 The Boeing Company Compression molding method and reinforced thermoplastic parts molded thereby
US8709321B2 (en) 2009-11-06 2014-04-29 The Boeing Company Compression molding method and reinforced thermoplastic parts molded thereby
WO2011056293A1 (en) * 2009-11-06 2011-05-12 The Boeing Company Compression molding method and reinforced thermoplastic parts molded thereby
US9238339B2 (en) 2013-02-21 2016-01-19 The Boeing Company Hybrid fastener and method of making the same
US9623612B2 (en) 2013-02-21 2017-04-18 The Boeing Company Method for fabricating composite fasteners
US10328643B2 (en) 2013-02-21 2019-06-25 The Boeing Company Apparatus for fabricating composite fasteners
US10350718B2 (en) 2013-02-21 2019-07-16 The Boeing Company Hybrid fastener and method of making the same
US9283706B2 (en) 2013-12-03 2016-03-15 The Boeing Company Method and apparatus for compression molding fiber reinforced thermoplastic parts
US9302434B2 (en) 2013-12-03 2016-04-05 The Boeing Company Thermoplastic composite support structures with integral fittings and method

Also Published As

Publication number Publication date
GB9910351D0 (en) 1999-06-30
GB2349600B (en) 2003-12-10

Similar Documents

Publication Publication Date Title
US5593762A (en) Inherently rigid laminate material containing plastic trimmings
Jayaraman Manufacturing sisal–polypropylene composites with minimum fibre degradation
DE2608112C2 (en) Process for the production of a laminated plastic product
US6375881B1 (en) Process for making a plastic material
CN102821933B (en) Method for producing an SMC multi-layer component
CN1190927A (en) Production of large composite structures
CN101761707A (en) Coextrusion composite polypropylene soft pipe and production method
WO2014037724A1 (en) Carbon fibre composites
DE19649907A1 (en) Multi-layer molded polymer composition and process for its manufacture
DE10255039A1 (en) Flat pressed composite product for vehicle interior lining panels comprises a lightweight core with internal chambers between outer layers of natural fiber and thermoplastic
WO1993000216A1 (en) Process for producing multiple-layer moulded bodies
GB2349600A (en) Composite component
DE3327149A1 (en) METHOD FOR THE PRODUCTION OF SEMI-PRODUCTS OR MOLDED PARTS FROM POLYPROPYLENE
EP0668142B1 (en) Method for coextrusion thermoformable panels
KR20160023967A (en) A preparation method of natural fiber-reinforced plastic for car interior and natural fiber-reinforced plastic for car interior prepared by the same
DE69838429T2 (en) METHOD FOR PRODUCING A SEPARABLE POLYOLEFIN RESIN FILM AND COMPOSITE FOAM
EP1834756B1 (en) Plastic moulded part with a decorative textile layer and method of manufacturing same
WO2008134505A2 (en) Process for molding composite pieces, device for molding such composites pieces obtained thereby
DE102015002107A1 (en) Process arrangement and method for producing a fiber-reinforced plastic component
CN102510801A (en) Moulded product for automotive panels
LU501121B1 (en) Method for manufacturing a composite filament and use thereof
DE3335669A1 (en) Injection-laminateable web-shaped plastics composite material, process for the production thereof and use thereof
EP1254008B1 (en) Method for manufacturing anti-crash panels and apparatus for carrying out the method
DE69821478T2 (en) Multi-layer film for the surface coating of moldings
KR101875579B1 (en) Manufacturing method for vehicle interior parts

Legal Events

Date Code Title Description
732E Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977)
732E Amendments to the register in respect of changes of name or changes affecting rights (sect. 32/1977)
PCNP Patent ceased through non-payment of renewal fee

Effective date: 20050506