JP7142006B2 - ハイブリッド繊維に基づく成形熱可塑性物品およびそれを形成する方法 - Google Patents
ハイブリッド繊維に基づく成形熱可塑性物品およびそれを形成する方法 Download PDFInfo
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- JP7142006B2 JP7142006B2 JP2019517218A JP2019517218A JP7142006B2 JP 7142006 B2 JP7142006 B2 JP 7142006B2 JP 2019517218 A JP2019517218 A JP 2019517218A JP 2019517218 A JP2019517218 A JP 2019517218A JP 7142006 B2 JP7142006 B2 JP 7142006B2
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Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
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- Nonwoven Fabrics (AREA)
Description
本出願は、2016年11月30日に出願された米国仮特許出願番号62/427,870の優先権を主張するものであり、それは参照により本明細書中に援用される。
本発明は概して、成形物品およびそれを作製する方法に関し、特に、補強非配向繊維と組み合わせて一方向性の配向された熱可塑性繊維層を用いた成形によって生産される物品に関する。
Claims (26)
- スタックであって、
ガラス繊維、炭素繊維、またはそれらの組み合わせを含む、少なくとも1層の刻まれた非配向繊維;および
前記少なくとも1層の刻まれた非配向繊維の両側の、長さおよび直径を有する第一のタイプの熱可塑性繊維からなる、少なくとも2層の一方向性および不織布の個々の熱可塑性繊維、
を備え、
前記少なくとも2層の一方向性および不織布の個々の熱可塑性繊維は、前記スタックの繊維含有量の40~98総重量パーセントを構成する、
スタック。 - 請求項1のスタックであって、
前記の少なくとも2層の一方向性の不織布の個々の熱可塑性繊維は、ガラス繊維、炭素繊維、または、第二のタイプの熱可塑性繊維の少なくとも1つの代替繊維を含む、
スタック。 - 請求項1のスタックであって、
前記の少なくとも2層の一方向性の不織布の個々の熱可塑性繊維は、長さにおける不連続性を含む、
スタック。 - 請求項3のスタックであって、
前記不連続性は、0.001mmから前記の長さの5%までの線形範囲を有する、
スタック。 - 請求項1のスタックであって、
複数の前記熱可塑性繊維は、それぞれ、前記の長さにおける1つまたは複数の不連続性を有する、
スタック。 - 請求項5のスタックであって、
前記の長さにおける前記の1つまたは複数の不連続性は、千鳥状である、
スタック。 - 請求項1から6のいずれか一項のスタックであって、
前記の第一のタイプの熱可塑性繊維は、前記スタックの40~98総重量パーセントを含む、
スタック。 - 請求項1から6のいずれか一項のスタックであって、
前記の長さは、0.5~3,000cmである、
スタック。 - 請求項1から6のいずれか一項のスタックであって、
前記直径は、0.01~0.7mmである、
スタック。 - 請求項1から6のいずれか一項のスタックであって、
前記の長さに沿った少なくとも1つのリテーナーラインをさらに備える、
スタック。 - 請求項1のスタックであって、
前記の少なくとも2層の一方向性の不織布の個々の熱可塑性繊維は、3~20層である、
スタック。 - 請求項11のスタックであって、
前記の3~20層は、互いから角変位される、
スタック。 - 請求項12のスタックであって、
前記の3~20層は、中央鏡面を規定する、
スタック。 - 請求項11のスタックであって、
前記の3~20層は、前記の少なくとも2層の一方向性の不織布の個々の熱可塑性繊維の連続する層の間で少なくとも15度、角変位される、
スタック。 - 請求項11のスタックであって、
前記の少なくとも1層の非配向繊維は、前記の3~20層の間に点在する、
スタック。 - 請求項1から6、11、12、13、14、または15のいずれか一項のスタックであって、
キュリーフィラーをさらに含む、
スタック。 - 請求項1から6、11、12、13、14、または15のいずれか一項のスタックであって、
マイクロスフェア、AlN、アルミナ、BN、カーボンブラックまたは黒鉛の少なくともフィラーをさらに含む、
スタック。 - 物品を形成する方法であって、
刻まれた非配向フィラー繊維を混合して非配向層を形成するステップ;
前記非配向層の両側を、一方向性の不織布の個々の熱可塑性繊維の層と接触させてスタックを形成するステップ、ここで、前記一方向性の不織布の個々の熱可塑性繊維は、前記スタックの繊維含有量の40~98総重量パーセントを構成する;
前記スタックを加熱して前記個々の熱可塑性繊維を互いに融合させて前記非配向フィラー繊維が中に埋め込まれた融合マトリックスを形成するステップ;および
前記融合マトリックスを冷却して前記物品を形成するステップ、
を含む、
方法。 - 請求項18の方法であって、
前記スタックは、前記加熱中に金型表面を有するスタックと接触されて、前記物品の形状を規定する、
方法。 - 請求項18の方法であって、
加熱前に前記スタック内に添加剤を分散させるステップをさらに含む、
方法。 - 請求項20の方法であって、
前記添加剤は、中空ガラスマイクロスフェアである、
方法。 - 請求項20の方法であって、
前記添加剤は、キュリー添加剤であり、
加熱は、全てまたは部分的に誘導加熱である、
方法。 - 請求項18から22のいずれか一項の方法であって、
前記加熱は、前記物品を表わす体積を規定する2以上の金型プラテンと接触して生じる、
方法。 - 請求項18から22のいずれか一項の方法であって、
前記物品は、車両コンポーネントである、
方法。 - 請求項1から6、11、12、13、14、または15のいずれか一項のスタックから形成される、
物品。 - 請求項18から22のいずれか一項の方法によって形成される、
物品。
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US62/427,870 | 2016-11-30 | ||
PCT/US2017/063379 WO2018102282A1 (en) | 2016-11-30 | 2017-11-28 | Hybrid fiber based molding thermoplastic article and process of forming same |
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- 2017-11-28 EP EP17875629.2A patent/EP3548274B8/en active Active
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Patent Citations (3)
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JP2007276476A (ja) | 2006-04-05 | 2007-10-25 | Azdel Inc | 補強皮を含む軽量複合熱可塑性シート |
WO2015031893A1 (en) | 2013-08-30 | 2015-03-05 | Continental Structural Plastics, Inc. | Overmolding with non-oriented fibers |
JP2016196624A (ja) | 2015-04-03 | 2016-11-24 | 国立大学法人岐阜大学 | 複合材料、複合材料の製造方法および成形品の製造方法 |
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WO2018102282A1 (en) | 2018-06-07 |
JP2020500735A (ja) | 2020-01-16 |
EP3548274A4 (en) | 2020-10-21 |
PT3548274T (pt) | 2023-09-14 |
EP3548274B1 (en) | 2023-07-19 |
US20210107236A1 (en) | 2021-04-15 |
EP3548274B8 (en) | 2023-08-23 |
EP3548274A1 (en) | 2019-10-09 |
US11987011B2 (en) | 2024-05-21 |
CA3037550A1 (en) | 2018-06-07 |
MX2019006322A (es) | 2019-10-15 |
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