US20190022896A1 - Fiber-reinforced molding compounds and methods of forming and using the same - Google Patents

Fiber-reinforced molding compounds and methods of forming and using the same Download PDF

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Publication number
US20190022896A1
US20190022896A1 US15/657,863 US201715657863A US2019022896A1 US 20190022896 A1 US20190022896 A1 US 20190022896A1 US 201715657863 A US201715657863 A US 201715657863A US 2019022896 A1 US2019022896 A1 US 2019022896A1
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US
United States
Prior art keywords
impregnated
fiber
fibers
extruder
polymeric material
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.)
Abandoned
Application number
US15/657,863
Other languages
English (en)
Inventor
VII Christopher Johnston
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.)
Aerlyte Inc
Original Assignee
Aerlyte 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 Aerlyte Inc filed Critical Aerlyte Inc
Priority to US15/657,948 priority Critical patent/US10011049B1/en
Priority to US15/657,934 priority patent/US20190022897A1/en
Priority to US15/657,741 priority patent/US10011048B1/en
Priority to US15/657,863 priority patent/US20190022896A1/en
Assigned to Aerlyte, Inc. reassignment Aerlyte, Inc. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: JOHNSTON, CHRISTOPHER, VII
Assigned to Aerlyte, Inc. reassignment Aerlyte, Inc. CHANGE OF ADDRESS Assignors: Aerlyte, Inc.
Priority to CN201880046679.4A priority patent/CN110997761B/zh
Priority to JP2020527726A priority patent/JP7156766B2/ja
Priority to CN202010139672.6A priority patent/CN111497179B/zh
Priority to KR1020207000850A priority patent/KR102298167B1/ko
Priority to MX2020000907A priority patent/MX2020000907A/es
Priority to PL18839199.9T priority patent/PL3638726T3/pl
Priority to EP18839199.9A priority patent/EP3638726B1/fr
Priority to PCT/US2018/033831 priority patent/WO2019022823A1/fr
Priority to EP23197333.0A priority patent/EP4273195A3/fr
Priority to CN202010149304.XA priority patent/CN111497180B/zh
Priority to ES18839199T priority patent/ES2963948T3/es
Publication of US20190022896A1 publication Critical patent/US20190022896A1/en
Priority to US16/394,615 priority patent/US10576662B2/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B15/00—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00
    • B29B15/08—Pretreatment of the material to be shaped, not covered by groups B29B7/00 - B29B13/00 of reinforcements or fillers
    • B29B15/10—Coating or impregnating independently of the moulding or shaping step
    • B29B15/12—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29B11/02—Making preforms by dividing preformed material, e.g. sheets, rods
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    • B29B11/00—Making preforms
    • B29B11/06—Making preforms by moulding the material
    • B29B11/10—Extrusion moulding
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    • B29B11/14—Making preforms characterised by structure or composition
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    • B29B15/122—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex
    • B29B15/125—Coating or impregnating independently of the moulding or shaping step of reinforcements of indefinite length with a matrix in liquid form, e.g. as melt, solution or latex by dipping
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    • B29B9/04—Making granules by dividing preformed material in the form of plates or sheets
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    • B29B9/14—Making granules characterised by structure or composition fibre-reinforced
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    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/58—Component parts, details or accessories; Auxiliary operations
    • B29B7/60—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material
    • B29B7/603—Component parts, details or accessories; Auxiliary operations for feeding, e.g. end guides for the incoming material in measured doses, e.g. proportioning of several materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
    • B29B7/00—Mixing; Kneading
    • B29B7/30—Mixing; Kneading continuous, with mechanical mixing or kneading devices
    • B29B7/58—Component parts, details or accessories; Auxiliary operations
    • B29B7/72—Measuring, controlling or regulating
    • 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
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/32—Component parts, details or accessories; Auxiliary operations
    • B29C43/34—Feeding the material to the mould or the compression means
    • B29C2043/3405—Feeding the material to the mould or the compression means using carrying means
    • B29C2043/3411—Feeding the material to the mould or the compression means using carrying means mounted onto arms, e.g. grippers, fingers, clamping frame, suction means
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
    • 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
    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0022—Combinations of extrusion moulding with other shaping operations combined with cutting
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/06—Rod-shaped
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/287—Raw material pre-treatment while feeding
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/285—Feeding the extrusion material to the extruder
    • B29C48/297—Feeding the extrusion material to the extruder at several locations, e.g. using several hoppers or using a separate additive feeding
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/355—Conveyors for extruded articles
    • 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
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
    • B29C48/79—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling of preformed parts or layers
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/0872—Prepregs
    • B29K2105/0881—Prepregs unidirectional
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
    • B29K2105/10—Cords, strands or rovings, e.g. oriented cords, strands or rovings
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/12—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of short lengths, e.g. chopped filaments, staple fibres or bristles
    • 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
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/25—Solid
    • B29K2105/253—Preform
    • 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
    • B29K2307/00—Use of elements other than metals as reinforcement
    • B29K2307/04—Carbon
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • C08K7/06—Elements
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
    • C08K7/00—Use of ingredients characterised by shape
    • C08K7/02—Fibres or whiskers
    • C08K7/04—Fibres or whiskers inorganic
    • C08K7/14—Glass

Definitions

  • the present disclosure relates to fiber-reinforced molding compounds and methods of forming and using the same, for example, for use in extruders and molding systems.
  • extrusion processes are also utilized to directly produce plastic parts. Such processes can be used to extrude a shaped product from a molding compound. Extrusion is used to create parts with a fixed cross-sectional profile. A composite or polymeric material in pellet form is fed into an extruder that heats and softens the composite or polymeric material. The molding compound is pushed out via a die, possibly into cool water that solidifies the extruded product. Extrusion can be utilized to create very complex cross-sections having excellent surface finishes.
  • W may be any one of the following values or within a range of any two of the following values: 6, 60, 120, 180, 240, 300, 360, 420, 480, 540 and 600 millimeters.
  • T may be any one of the following values or within a range of any two of the following values: 0.05, 0.1, 0.2, 0.3, 0.4, 0.5 and 1.0 millimeters.
  • a heating system 50 may be included in the extrusion system 10 .
  • the heating system 50 may include one or more heaters or heating elements 52 .
  • the heating elements 52 may be any suitable heating equipment or device, such as hot air heaters, flame heaters, infrared (IR) heaters, conduction heaters, induction heaters, lasers, or others, as well as combinations thereof.
  • the heating elements 52 may be positioned proximate the inlet port 16 such that they are configured to heat the pre-impregnated continuous strand 18 prior to it entering the inlet port 16 (e.g., directly before entering the port).
  • the pre-impregnated continuous strand 18 may be the pre-impregnated continuous tape 46 .
  • the heating system 50 may be configured to heat the source material such that it is softened, but still solid (e.g., below the melting temperature of the polymeric material). This may reduce the amount of extra heat/energy that must be added by the extruder to melt the polymeric material.
  • the heating system 50 may be configured to heat the source material to at or above the melting temperature of the polymeric material, such that it is at least partially or completely melted. This may even further reduce the energy needed to be added by the extruder and may facilitate the extrusion process.
  • Softening or melting the source material also eliminates or minimizes the solid-melt interface where unmelted source material damages fiber during contact within the melt stream.
  • a tape or flake format further protects fiber damage by the compliance inherent in its form factor and facilitates heat transfer.
  • the perpendicular cuts can be used to generate same length inputs of one starting length into the extruder. In another embodiment, the perpendicular cuts can be used to generate multiple length inputs of those specific sizes based on the relative proportion of each cut. In an alternative embodiment, the source material can be cut at an angle to provide a continuous distribution of fiber lengths between a minimum and maximum flake length.
  • FIGS. 6A, 6B and 6C depict further examples of pre-impregnated continuous tape 70 , 72 , 74 , respectively, divided into pre-impregnated flakes having a predetermined distribution of fiber lengths.
  • Pre-impregnated continuous tape 70 , 72 , 74 each include continuous reinforcement fibers. These reinforcement fibers are divided according the dividing lines 76 , 78 , 80 shown on pre-impregnated continuous tape 70 , 72 , 74 , respectively.
  • pre-impregnated continuous tape 70 is divided into flakes 82 by dividing lines 76 , and each flake has an equal length A.
  • FIG. 6A pre-impregnated continuous tape 70 is divided into flakes 82 by dividing lines 76 , and each flake has an equal length A.
  • pre-impregnated continuous tape 72 is divided into flakes 84 by dividing lines 78 , and each flake has either length A or length B.
  • length A can be 5 millimeters and length B can be 10 millimeters.
  • the dividing scheme identified in FIG. 6B can be used to generate a uniform distribution of flakes having half of the flakes with length A and half of the flakes length B. This dividing scheme could be used to divide the flakes into three or more different predetermined lengths in a predetermined pattern to generate a uniform or non-uniform distribution of the three or more different predetermine lengths.
  • pre-impregnated continuous tape 74 is divided into flakes 86 by dividing lines 80 .
  • Each flake is a quadrilateral having a side with a length A and an opposing side with a length B. These flakes deliver a uniform distribution of fibers ranging from length A to length B. In one example, length A can be 5 millimeters and length B can be 10 millimeters.
  • the term flake may refer to a shape having a relatively consistent length and width and a thickness that is small relative to the length and width. If the flakes 60 are formed from a tape, such as tape 46 , then the flakes will have the same thickness and width as the tape, but will have a finite length.
  • the flakes 60 may have continuous fibers disposed therein, similar to the tape 46 . The fibers may extend unbroken from one side of the flake to the other or may have other patterns, similar to those described above for the tape 46 .
  • the flakes 60 may be formed immediately prior to being introduced into an extruder.
  • a continuous source material 62 may be fed through a cutting device 64 to cut, shred or otherwise divide the continuous source material 62 into a plurality of discrete flakes 60 .
  • the flakes 60 may then fall by gravity into an inlet port 66 and be fed to the extruder for melting and processing.
  • the continuous source material 62 may be a tape, such as tape 46 described above.
  • the continuous source material 62 may be fed to the cutting device 64 using any suitable means, such as rollers or a conveyor belt.
  • the cutting device 64 may include any suitable cutting element or elements 68 , such as cutting rollers, chopping blades, lasers, etc.
  • a heating system such as the one shown and described with respect to FIG. 3 , may be included and configured to heat the flakes 60 as they fall to the inlet port 66 .
  • the flakes 60 may be generated and collected prior to introduction into the extruder.
  • the flakes 60 may fall into a collector, such as a bin or container.
  • the flakes 60 may then be stored in bulk until an extruding and molding operation is to be performed.
  • the flakes may be fed into the extruder in a manner similar to how conventional pellets are introduced, such as via a hopper.
  • flakes may melt faster than pellets, especially when introduced into an existing melt stream due to their large surface area and small thickness. Also, flakes are not rigid like pellets and can more easily conform without breaking when subjected to shear prior to completely being melted.
  • the system 100 may be similar to system 10 , with similar components sharing the same numerals. Differences in the two systems are described below.
  • the system 100 may include an extruder 12 .
  • the extruder 12 may include an inlet port 102 for receiving one or more source materials 104 in a rear end or portion 20 of the extruder 12 .
  • the screw(s) 14 may advance the source material 102 within the extruder and rotate, mix, shear, and/or heat the material as it moves to form a melt stream 22 by the time the material reaches a front end or portion 24 of the extruder 12 .
  • the extruder 12 may include a second inlet port 106 , which may be proximate the inlet port 102 or may be downstream from the inlet port 102 (towards the front of the extruder).
  • the second inlet port 106 may be downstream of the inlet port 102 , such as shown in FIG. 6 .
  • the source material(s) 104 may be at least partially melted by the time they reach the region of the extruder where the second inlet port 106 is located.
  • such compounding of the polymeric materials with other constituents may be done within a separate extruder and introduced as a melt stream into a second extruder into which the fiber-reinforced source material is introduced.
  • the source material(s) 104 may be completely melted when they reach the region of the second inlet port 106 .
  • the fiber-reinforced source material 108 may include the fiber type(s) and/or polymeric materials described above for the pre-impregnated continuous strand 18 .
  • the fiber-reinforced source material 108 may include fibers such as carbon fiber, glass fiber, aramid fibers, or others, or a combination thereof.
  • the fiber-reinforced source material 108 may include thermoplastic or thermoset polymeric materials as the matrix material.
  • the downstream introduction of the fiber-reinforced source material 108 may create a fiber-reinforced material having an intermediate fiber concentration between the source material 104 and the fiber-reinforced source material 108 .
  • Fiber-reinforced source material 108 have fibers already coated with a resin, thereby protecting them from the upstream melt stream produced by material 104 , which may have a different matrix resin or composition that is not compatible with the impregnation process due to a higher viscosity, abrasive fillers, etc.
  • FIG. 8 depicts an extrusion system 200 according to an embodiment of the present disclosure.
  • Extrusion system 200 includes an upstream port 202 , a downstream port 204 , and an exit port 206 .
  • a source material can be dosed (e.g., using a gravimetric feeding process) into the upstream port 202 .
  • the source material can be supplied as solid pellets or pellets having unidirectional fibers either pre-impregnated with resin or wire coated around the circumference of a core of fibers so that the initial length of the fiber is fixed by the length of the pellets.
  • These pellets can be dosed with other pellets made from neat resin or compounds that include additives, fillers, blowing agents or other functionalization required by the process or part.
  • a composite material is dosed into downstream port 204 after the melt stream has been established from the source material of upstream port 202 .
  • the composite material of downstream port 204 can be reinforcing fibers pre-impregnated by a matrix material.
  • the composite material can be dosed as pellets, tape or flake, for example.
  • the fiber concentration of the composite material can be higher than the fiber concentration of the molding compound and the source material.
  • the source material of upstream port 202 and the composite material of downstream port 204 can each include one or more resins.
  • a resin of the same family used to produce the composite material can be used in the source material.
  • Non-limiting examples of resin families include polypropylene, polyamide, and polyethylene terephthalate.
  • the resin in the source material can have a higher molecular weight or viscosity, which would be otherwise unsuitable for initial impregnation of the fibers of the composite material, but enhances the toughness or processability of the molding compound exiting the extrusion system 200 at exit port 206 .
  • FIG. 9A depicts an extrusion system 300 according to another embodiment of the present disclosure.
  • Extrusion system 300 includes input port 302 and exit port 312 .
  • a pre-impregnated continuous strand of composite material 304 in any form disclosed herein, including a pre-impregnated continuous tape is dosed into port 302 .
  • the pre-impregnated continuous strand may have a substantially uniform cross-section, e.g., not deviating more than ⁇ 0%, 0.1%, 0.5%, 1%, 2%, 3%, 4%, 5% or 10% of the cross-sectional area in any cross-section along the length of the continuous strand.
  • Non-limiting examples of cross-sectional shapes include elliptical ( FIG.
  • FIG. 9B oblong ( FIG. 9C ), rectangular ( FIG. 9D ), or tape ( FIG. 9E ).
  • One more cross-sectional shaped pre-impregnated continuous strands may be introduced in input port 302 sequentially or at the same time to insure sufficient material throughput.
  • one 200 mm wide tape-shaped strand or 2 100 mm wide tape shaped strands or 10 circular shaped strands may be introduced into input port 302 at the same time to insure sufficient material throughput.
  • one embodiment of the present disclosure includes decoupling the impregnation of the fiber and to produce the pre-impregnated continuous strand separately under its own optimum process conditions and to subsequently take the pre-impregnated continuous strand and feed it at a much higher rate relevant to the process that converts the strand into a composite part.
  • FIG. 10 depicts an extrusion system 400 according to yet another embodiment of the present disclosure.
  • Extrusion system 400 includes input port 402 and exit port 404 .
  • a pre-impregnated continuous tape 406 of composite material is fed into cutting element 408 .
  • the pre-impregnated continuous tape 406 can include continuous, discontinuous, or a combination of fiber lengths formulated for an intended application.
  • the pre-impregnated continuous tape 406 can be delivered from a coil 410 of the composite material.
  • the cutting element 408 divides pre-impregnated continuous tape 406 into flakes 412 . Examples of form factors for the flakes are disclosed above.
  • flakes are more flexible then pellets, as the flakes initially encounter the screw of the extruder and begin the melt phase, they are less likely to cause damage to adjacent flakes.
  • flakes have a preferential aspect ratio in terms of area/unit mass, and therefore, the flake will absorb heat more rapidly and evenly than pellets, making the flake less prone as it melts to damage fiber within the developing melt stream.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Medicinal Chemistry (AREA)
  • Polymers & Plastics (AREA)
  • Organic Chemistry (AREA)
  • Health & Medical Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Wood Science & Technology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Inorganic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Reinforced Plastic Materials (AREA)
  • Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Moulding By Coating Moulds (AREA)
US15/657,863 2017-07-24 2017-07-24 Fiber-reinforced molding compounds and methods of forming and using the same Abandoned US20190022896A1 (en)

Priority Applications (16)

Application Number Priority Date Filing Date Title
US15/657,948 US10011049B1 (en) 2017-07-24 2017-07-24 Fiber-reinforced molding compounds and methods of forming and using the same
US15/657,934 US20190022897A1 (en) 2017-07-24 2017-07-24 Fiber-reinforced molding compounds and methods of forming and using the same
US15/657,741 US10011048B1 (en) 2017-07-24 2017-07-24 Fiber-reinforced molding compounds and methods of forming and using the same
US15/657,863 US20190022896A1 (en) 2017-07-24 2017-07-24 Fiber-reinforced molding compounds and methods of forming and using the same
CN202010149304.XA CN111497180B (zh) 2017-07-24 2018-05-22 纤维增强型模塑料、以及形成和使用该纤维增强型模塑料的方法
ES18839199T ES2963948T3 (es) 2017-07-24 2018-05-22 Procedimiento para producir un compuesto de moldeo reforzado con fibra de carbono
KR1020207000850A KR102298167B1 (ko) 2017-07-24 2018-05-22 섬유-보강 몰딩 화합물 및 이를 형성하는 방법 및 사용하는 방법
PCT/US2018/033831 WO2019022823A1 (fr) 2017-07-24 2018-05-22 Composés de moulage renforcés par des fibres et procédés de formation et d'utilisation de ceux-ci
CN202010139672.6A CN111497179B (zh) 2017-07-24 2018-05-22 纤维增强型模塑料、以及形成和使用该纤维增强型模塑料的方法
CN201880046679.4A CN110997761B (zh) 2017-07-24 2018-05-22 纤维增强型模塑料、以及形成和使用该纤维增强型模塑料的方法
MX2020000907A MX2020000907A (es) 2017-07-24 2018-05-22 Compuestos de moldeo reforzados con fibra y metodos de formacion y uso de los mismos.
PL18839199.9T PL3638726T3 (pl) 2017-07-24 2018-05-22 Sposób wytwarzania masy formierskiej wzmocnionej włóknem węglowym
EP18839199.9A EP3638726B1 (fr) 2017-07-24 2018-05-22 Procédé de production d'une matière à mouler renforcée par des fibres de carbone
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