JP7189773B2 - 粉体塗装層を含むプリプレグ、コア、及び複合物品 - Google Patents
粉体塗装層を含むプリプレグ、コア、及び複合物品 Download PDFInfo
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- JP7189773B2 JP7189773B2 JP2018561999A JP2018561999A JP7189773B2 JP 7189773 B2 JP7189773 B2 JP 7189773B2 JP 2018561999 A JP2018561999 A JP 2018561999A JP 2018561999 A JP2018561999 A JP 2018561999A JP 7189773 B2 JP7189773 B2 JP 7189773B2
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- B32B2264/02—Synthetic macromolecular particles
- B32B2264/0214—Particles made of materials belonging to B32B27/00
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- B32B2305/02—Cellular or porous
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- B—PERFORMING OPERATIONS; TRANSPORTING
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- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2423/00—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers
- C08J2423/02—Characterised by the use of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Derivatives of such polymers not modified by chemical after treatment
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- C08J2423/12—Polypropene
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- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2475/00—Characterised by the use of polyureas or polyurethanes; Derivatives of such polymers
- C08J2475/04—Polyurethanes
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- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2477/00—Characterised by the use of polyamides obtained by reactions forming a carboxylic amide link in the main chain; Derivatives of such polymers
Description
本出願は、2016年5月26日に出願された米国仮特許出願第62/341,989に関連し、この出願に基づく優先権を主張し、またこの出願の利益を主張する。この出願の開示全体は、ここにあらゆる目的のため参照により本明細書に組み込まれる。
特定の実施形態が添付の図面を参照しつつ説明される。
コア層上に配置された粉体塗装層を含む複数の複合物品を作製した。表1には、使用した異なる粉末の種類がまとめられている。これらの異なる粉末のいくつかは、以降の他の実施例において別個に使用した。
粉体塗装プロセスを使用して、軽量強化熱可塑性複合板(SuperliteTM複合物品)の上を実施例1のそれぞれの粉末で別々に塗装した。このプロセスは、図16に示されるものと同様の構成を使用した。使用した積層温度は140~200℃であった。使用したライン速度は5~30m/分であった。使用したニップギャップ距離は0.5~8mmであった。
表1からのコポリアミド粉末を、ポリプロピレンとガラス繊維とを含むSuperliteTM板上に塗装した。次いで、加熱されている熱成形機の中に板を入れ、ここで、SuperliteTM板の粉末またはフィルムを有する側に生地(この実施例では2層積層品または2層積層生地)を付加させた。その後、複合材料を、厚さ2.25mm(表2)及び厚さ3.0mm(表3)を含む、異なる厚さに成形した。粉体塗装層または対照フィルムに結合された生地層の剥離強度を、2010年付けのASTM D903の180°剥離により測定した。SuperliteTM板の坪量は900gsmであった。
Co-PA粉末を用いたSuperliteTM板の圧縮に対する耐性も測定した。使用した複合材料は、表3で使用したもの(80gsmのCo-PA粉末層)と同じであった。結果を表4に示す。表中の値は、表4に列挙した様々な荷重を板にかけた後のmm単位での得られた厚さである。
様々な条件に曝された後の、Co-PA粉体塗装板の縦方向の剥離強度を試験した。結果を表5に示す。環境サイクルとは、2010年付けのFord-BN 151-05試験で定められた条件を指す。使用した剥離強度試験は実施例3で使用したものと同じであった。
表1からのポリプロピレン粉末材料を、異なる坪量でSuperliteTM板上に塗装した。次いで、加熱されている熱成形機の中に板を入れ、ここで、SuperliteTM板の粉末またはフィルムを有する側に生地(この実施例では不織布)を付加させた。その後、複合材料を、厚さ3.25mm(表6)及び厚さ3.5mm(表7)を含む、異なる厚さに成形した。板の特定の物理的特性を測定し、98gsmのポリプロピレン(PP)フィルムと不織布とを含む対照のSuperliteTM板と比較した。SuperliteTM板の坪量は表6では1000gsmであり、表7では1300gsmであった。剥離強度は、2010年付けのASTM D903の180°剥離を使用して測定した。
PP粉末を用いたSuperliteTM板の圧縮に対する耐性も測定した。使用した複合材料は、表7で使用したもの(70gsmのPP粉末層)と同じであった。結果を表8に示す。表中の値は、表に列挙した様々な荷重を板にかけた後のmm単位での得られた厚さである。
表1からの熱可塑性ポリウレタン(TPU)粉末材料を、SuperliteTM板上に塗装した。次いで、加熱されている熱成形機の中に板を入れ、ここで、SuperliteTM板の粉末またはフィルムを有する側に生地(表9については2層積層生地)を付加させた。その後、複合材料を厚さ3.0mmに成形した。板の特定の物理的特性を測定し、70gsm及び80gsmのPP/Co-PAフィルム(表9)と同じ種類の生地層とを含む対照のSuperliteTM板と比較した。SuperliteTM板の坪量は表9では1000gsmであった。剥離強度は、2010年付けのASTM D903の180°剥離を使用して測定した。
熱可塑性ポリウレタン(TPU)粉末材料(80gsm)を、ポリプロピレンとガラス繊維とを含む複合板上に粉体塗装した。各板の坪量に関し、1枚の板には80gsmのPP/CoPAフィルムが含まれ、TPUコーティングを有する板にはフィルムが含まれていなかった。合計4枚の板のために、2つの異なる板の坪量(800gsmのXL2TMコアと900gsmのSuperliteTMコア)を使用した。4枚の板の特定の物理的性質を測定し、比較した。それぞれの板を加熱されている熱成形機の中に入れ、ここで、板のTPU粉末またはPP/Co-PAフィルムを有する側に生地(この実施例では2層積層品または2層積層生地(PU/ポリエステル))を付加させた。その後、複合材料を、厚さ3.5mmのXL2TMコア及び厚さ2.5mmのSuperliteTMコアを用いて厚さ2.5mmまたは3.5mmに成形した。
様々な坪量の粉体塗装されたPP板を、実施例9のTPU被覆板と同様の方法を用いて製造した。使用した坪量は、800gsm(ポリプロピレン、ガラス繊維、及びマイクロスフェアを含むXLTTMコア)、1400gsm(ポリプロピレン及びガラス繊維を含むSuperliteTMコア)、1600gsm(ポリプロピレン及びガラス繊維を含むSuperliteTMコア)、及び2000gsm(ポリプロピレン及びガラス繊維を含むSuperliteTMコア)であった。この実施例では、PP粉体塗装板にはカバー層は存在しなかった。80gsmのPP粉末を有する板の音響測定を、98gsmの固体PPフィルムを有する板と比較した(図21及び22)。80gsmのPP粉末を有する板の音響測定を、88gsmの有孔PPフィルムを有する板と比較した(図23及び24)。結果を図21~24の中でグラフにより示す。
実施例9の板について、坪量及び灰分(表10)、周囲温度での剥離試験(表11)、90℃での環境サイクル後の剥離試験(表12)、及び流れ抵抗(表13)を含む様々な物理的パラメータを試験した。表11で試験した板はカバー材料を全く含んでおらず、成形前の製造したままの状態で試験した。
表14に示される様々なコアについて、剥離強度測定を行った。表14は、周囲条件と熱エージング後の両方の結果を示している。表14で試験した板は、2層積層カバー材料を含んでいた。
Claims (12)
- ポリオレフィン熱可塑性材料によって一体に保持された強化ガラス繊維のウェブを含み、前記強化ガラス繊維は30質量%以上70質量%以下存在し、前記ポリオレフィン熱可塑性材料は20質量%以上80質量%以下存在する多孔質コア層であって、前記多孔質コア層の空隙率は前記多孔質コア層の少なくとも10体積%であり、前記多孔質コア層が300gsm~3000gsmの坪量を有する前記多孔質コア層と、
前記多孔質コア層上に配置されている熱可塑性ポリマー粉末を含む粉体塗装層と、
を含む熱可塑性複合物品であって、前記熱可塑性ポリマー粉末の平均粒子サイズが、前記粉体塗装層と前記多孔質コア層との間に界面が得られるように選択され、前記粉体塗装層の実質的に全ての前記配置されている粉末が前記界面の上に存在し、前記熱可塑性ポリマー粉末は前記粉体塗装層内において前記粉体塗装層の50質量%以上99質量%以下存在し、前記粉体塗装層が約20gsm~約200gsmの坪量を有し、
前記粉体塗装層の上に配置されたスキン層を更に含み、前記粉体塗装層が、2010年付けのASTM D903の180°剥離により試験される、縦方向に少なくとも125N/m及び横方向に少なくとも125N/mの平均剥離強度を前記スキン層に付与するために有効である、熱可塑性複合物品。 - 前記粉体塗装層の前記熱可塑性ポリマー粉末がポリオレフィンである、請求項1に記載の熱可塑性複合物品。
- 前記多孔質コア層の前記ポリオレフィン熱可塑性材料が、ポリエチレン、ポリプロピレン、及びこれらの混合物からなる群から選択される、請求項1に記載の熱可塑性複合物品。
- 前記粉体塗装層の前記熱可塑性ポリマー粉末がポリウレタン粉末またはポリアミド粉末またはコポリアミド粉末またはポリプロピレン粉末を含む、請求項1に記載の熱可塑性複合物品。
- 前記多孔質コア層がロフティング剤を更に含む、請求項1に記載の熱可塑性複合物品。
- 前記多孔質コア層と前記粉体塗装層との間に障壁が存在せず、結果として前記粉体塗装層が前記多孔質コア層の上に直接配置される、請求項1に記載の熱可塑性複合物品。
- 前記スキン層が、フィルム、フリム、スクリム、箔、紙、織布、不織布、発泡体、無機コーティング、有機コーティング、熱可塑性コーティング、及び熱硬化性材料コーティングからなる群から選択される、請求項1に記載の熱可塑性複合物品。
- 前記スキン層の上に配置された装飾層を更に含む、請求項1に記載の熱可塑性複合物品。
- 前記多孔質コア層が、前記粉体塗装層中の前記熱可塑性ポリマー粉末の熱可塑性とは異なる熱可塑性材料を更に含む、請求項1に記載の熱可塑性複合物品。
- 前記多孔質コア層が、前記多孔質コア層が、前記粉体塗装層中の前記熱可塑性ポリマー粉末の熱可塑性と同じ熱可塑性材料を更に含む、請求項1に記載の熱可塑性複合物品。
- 前記粉体塗装層が、2010年付けのASTM D903の180°剥離により試験される、縦方向に少なくとも390N/m及び横方向に少なくとも390N/mの平均剥離強度を前記スキン層に付与するために有効である、請求項1に記載の熱可塑性複合物品。
- 前記粉体塗装層が、2010年付けのASTM D903の180°剥離により試験される、縦方向に少なくとも250N/m及び横方向に少なくとも250N/mの平均剥離強度を前記スキン層に付与するために有効である、請求項1に記載の熱可塑性複合物品。
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CN109476113B (zh) | 2021-06-25 |
US11090899B2 (en) | 2021-08-17 |
KR20190013874A (ko) | 2019-02-11 |
AU2017268789A1 (en) | 2019-01-17 |
AU2022201884A1 (en) | 2022-04-21 |
JP2019516594A (ja) | 2019-06-20 |
US20220161516A1 (en) | 2022-05-26 |
CA3025499A1 (en) | 2017-11-30 |
EP3463852A1 (en) | 2019-04-10 |
WO2017205600A1 (en) | 2017-11-30 |
EP3463852A4 (en) | 2020-01-15 |
KR102550397B1 (ko) | 2023-07-03 |
US20180015688A1 (en) | 2018-01-18 |
CN109476113A (zh) | 2019-03-15 |
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