WO2000037239A1 - Method and apparatus for blow molding large reinforced plastic parts - Google Patents
Method and apparatus for blow molding large reinforced plastic parts Download PDFInfo
- Publication number
- WO2000037239A1 WO2000037239A1 PCT/US1999/029991 US9929991W WO0037239A1 WO 2000037239 A1 WO2000037239 A1 WO 2000037239A1 US 9929991 W US9929991 W US 9929991W WO 0037239 A1 WO0037239 A1 WO 0037239A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- motor vehicle
- bumper
- support structure
- radiator
- reinforcement particles
- Prior art date
Links
- 238000000034 method Methods 0.000 title claims abstract description 29
- 239000002990 reinforced plastic Substances 0.000 title claims abstract description 6
- 238000000071 blow moulding Methods 0.000 title description 21
- 239000002245 particle Substances 0.000 claims abstract description 83
- 230000002787 reinforcement Effects 0.000 claims abstract description 67
- 239000004033 plastic Substances 0.000 claims abstract description 33
- 229920003023 plastic Polymers 0.000 claims abstract description 33
- 239000012815 thermoplastic material Substances 0.000 claims abstract description 26
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 13
- 238000000465 moulding Methods 0.000 claims abstract description 4
- 239000012530 fluid Substances 0.000 claims description 24
- 238000005507 spraying Methods 0.000 claims description 4
- 210000003195 fascia Anatomy 0.000 claims description 3
- 239000002105 nanoparticle Substances 0.000 description 13
- 229910052500 inorganic mineral Inorganic materials 0.000 description 12
- 239000011707 mineral Substances 0.000 description 12
- 239000000463 material Substances 0.000 description 10
- 238000011068 loading method Methods 0.000 description 8
- 239000003365 glass fiber Substances 0.000 description 6
- 229920000098 polyolefin Polymers 0.000 description 6
- 230000008901 benefit Effects 0.000 description 5
- 239000000945 filler Substances 0.000 description 5
- 239000010410 layer Substances 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- 238000004299 exfoliation Methods 0.000 description 4
- 238000009863 impact test Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 229920000642 polymer Polymers 0.000 description 4
- 229920002397 thermoplastic olefin Polymers 0.000 description 4
- GUJOJGAPFQRJSV-UHFFFAOYSA-N dialuminum;dioxosilane;oxygen(2-);hydrate Chemical compound O.[O-2].[O-2].[O-2].[Al+3].[Al+3].O=[Si]=O.O=[Si]=O.O=[Si]=O.O=[Si]=O GUJOJGAPFQRJSV-UHFFFAOYSA-N 0.000 description 3
- 239000007789 gas Substances 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 229910052901 montmorillonite Inorganic materials 0.000 description 3
- 210000003739 neck Anatomy 0.000 description 3
- -1 polypropylene, ethylene-propylene copolymers Polymers 0.000 description 3
- 239000004721 Polyphenylene oxide Substances 0.000 description 2
- 239000000470 constituent Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 239000006185 dispersion Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012764 mineral filler Substances 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 239000008188 pellet Substances 0.000 description 2
- 229920001707 polybutylene terephthalate Polymers 0.000 description 2
- 229920000139 polyethylene terephthalate Polymers 0.000 description 2
- 229920006380 polyphenylene oxide Polymers 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229910000275 saponite Inorganic materials 0.000 description 2
- 229910052604 silicate mineral Inorganic materials 0.000 description 2
- 229920001169 thermoplastic Polymers 0.000 description 2
- 239000004416 thermosoftening plastic Substances 0.000 description 2
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical compound C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 description 1
- 229920007019 PC/ABS Polymers 0.000 description 1
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 229920005601 base polymer Polymers 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 230000002939 deleterious effect Effects 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229910000271 hectorite Inorganic materials 0.000 description 1
- KWLMIXQRALPRBC-UHFFFAOYSA-L hectorite Chemical compound [Li+].[OH-].[OH-].[Na+].[Mg+2].O1[Si]2([O-])O[Si]1([O-])O[Si]([O-])(O1)O[Si]1([O-])O2 KWLMIXQRALPRBC-UHFFFAOYSA-L 0.000 description 1
- 150000004679 hydroxides Chemical class 0.000 description 1
- 239000011229 interlayer Substances 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002991 molded plastic Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 239000004417 polycarbonate Substances 0.000 description 1
- 229920000515 polycarbonate Polymers 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000010008 shearing Methods 0.000 description 1
- 239000011734 sodium Substances 0.000 description 1
- 229910052708 sodium Inorganic materials 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 229910052902 vermiculite Inorganic materials 0.000 description 1
- 239000010455 vermiculite Substances 0.000 description 1
- 235000019354 vermiculite Nutrition 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
- B62D25/08—Front or rear portions
- B62D25/082—Engine compartments
- B62D25/084—Radiator supports
-
- 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
- B29C44/00—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles
- B29C44/02—Shaping by internal pressure generated in the material, e.g. swelling or foaming ; Producing porous or cellular expanded plastics articles for articles of definite length, i.e. discrete articles
- B29C44/12—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements
- B29C44/14—Incorporating or moulding on preformed parts, e.g. inserts or reinforcements the preformed part being a lining
- B29C44/146—Shaping the lining before foaming
-
- 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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/0005—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor characterised by the material
-
- 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
- B29C49/00—Blow-moulding, i.e. blowing a preform or parison to a desired shape within a mould; Apparatus therefor
- B29C49/02—Combined blow-moulding and manufacture of the preform or the parison
- B29C49/04—Extrusion blow-moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
- B62D29/04—Superstructures, understructures, or sub-units thereof, characterised by the material thereof predominantly of synthetic material
- B62D29/043—Superstructures
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3005—Body finishings
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
- B29L2031/3044—Bumpers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60K—ARRANGEMENT OR MOUNTING OF PROPULSION UNITS OR OF TRANSMISSIONS IN VEHICLES; ARRANGEMENT OR MOUNTING OF PLURAL DIVERSE PRIME-MOVERS IN VEHICLES; AUXILIARY DRIVES FOR VEHICLES; INSTRUMENTATION OR DASHBOARDS FOR VEHICLES; ARRANGEMENTS IN CONNECTION WITH COOLING, AIR INTAKE, GAS EXHAUST OR FUEL SUPPLY OF PROPULSION UNITS IN VEHICLES
- B60K11/00—Arrangement in connection with cooling of propulsion units
- B60K11/02—Arrangement in connection with cooling of propulsion units with liquid cooling
- B60K11/04—Arrangement or mounting of radiators, radiator shutters, or radiator blinds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R19/00—Wheel guards; Radiator guards, e.g. grilles; Obstruction removers; Fittings damping bouncing force in collisions
- B60R19/02—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
- B60R19/18—Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by the cross-section; Means within the bumper to absorb impact
- B60R2019/1806—Structural beams therefor, e.g. shock-absorbing
- B60R2019/1833—Structural beams therefor, e.g. shock-absorbing made of plastic material
- B60R2019/184—Blow moulded
Definitions
- the present invention relates to blow molding methods and apparatuses, and, more particularly, a blow molding method and apparatus for producing large, reinforced plastic parts.
- One example of this can be seen in radiator supports for automobiles. Design engineers are now integrating many features into the radiator support to reduce tooling and manufacturing costs.
- blow molding techniques for forming such parts has not been practical due to the structural characteristics of the plastic material conventionally used in blow molding techniques. That is, the ability to blow molding large complex parts is limited by the fact that the parts produced can be only so large or so thin before the parts lose their structural integrity and impact resistance.
- the present invention provides a method for blow molding large, plastic parts. Accordingly, the present invention provides a method for molding large parts,
- a reinforced plastic melt comprising at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material, the reinforcement particles comprising less than 15% of a total volume of the plastic melt, and at least 50% of the reinforcement particles having a thickness of less than about 20 nanometers, and at least 99% of the reinforcement particles having a thickness of less than about 30 nanometers; communicating a tubular formation of the plastic melt to a mold assembly having a mold cavity defined by mold surfaces, the mold surfaces corresponding to a configuration of the part to be molded, an amount of the plastic melt communicated to the mold assembly being sufficient to form a part having a weight of at least 2 pounds and a total surface area of at least 400 sq. inches; applying pressurized gas to an interior of said tubular formation to expand the tubular formation into conformity with the mold surfaces; solidifying the plastic melt to form the part; and removing said part from said mold assembly.
- a substantially hollow, integrally formed radiator and light support structure for a motor vehicle is formed from at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material.
- the reinforcement particles comprise less than 15% of a total volume of the integrally formed radiator and light support structure, at least 50% of the reinforcement particles have a thickness of less than about 20 nanometers, and at least 99% of the reinforcement particles have a thickness of less than about 30 nanometers.
- the structure comprises a radiator frame portion, having apertures for securing a motor vehicle radiator to the support structure.
- the recesses of the support structure are constructed and arranged to mount headlights for the motor vehicle.
- the recesses have apertures for receiving electrical connecting portions of the lights.
- a fluid consuming component is constructed and arranged to be mounted on and used by the motor vehicle.
- a conduit communicates the fluid consuming component with the sealed interior of the hollow bumper, thus permitting said hollow sealed bumper to serve as a fluid reservoir for the fluid consuming component.
- a substantially hollow, integrally formed bumper and radiator and light support structure assembly for a motor vehicle.
- the assembly is formed from at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material.
- the reinforcement particles comprise less than 15% of a total volume of the support structure assembly, at least 50% of the reinforcement particles have a thickness of less than about 20 nanometers, and at least 99% of the reinforcement particles have a thickness of less than about 30 nanometers.
- the integrally formed assembly includes i) a hollow radiator frame portion, and apertures formed in the frame portion for securing a motor vehicle radiator to the frame portion, ii) a pair of light receiving recesses constructed and arranged to mount for the motor vehicle. Apertures are formed in the recesses for
- a hollow bumper portion constructed and arranged to be mounted to a front end of a motor vehicle.
- FIGS. 1-3 are cross sectional views of a blow molding assembly, and illustrating various steps used in a blow molding operation in accordance with one aspect of the present invention
- FIG. 4 is a perspective view of a blow-molded combination radiator support and light support structure in accordance with a further aspect of the present invention
- FIG. 5 is a perspective view of a motor vehicle, with certain components removed to better reveal others, and illustrating the combination of a hollow bumper, fluid consuming component, and conduit for communicating the bumper with the fluid consuming component in accordance with yet a further aspect of the present invention
- FIG. 6 is an enlarged perspective view of the front end of the motor vehicle illustrated in
- FIG. 5 The first figure.
- FIG. 7 is a perspective view of an integral, blow-molded bumper and radiator support and headlight support assembly in accordance with yet another aspect of the present invention. DESCRIPTION OF THE PREFERRED EMBODIMENT
- FIG. 1 Illustrated in Figure 1 is a blow molding assembly, generally indicated at 10, in accordance with the present invention.
- the assembly 10 includes an extruder nozzle 12
- the tubular head assembly 14 is provided with an internal tubular core 18.
- An ejecting mechanism 24 is disposed in the space between the tubular head assembly 14 and the core 18.
- a hot plastic melt 20 is supplied through an extruder nozzle 12 into the tubular head assembly 14.
- a hot plastic preform 25 is produced in the cavity between the core 18 and the assembly 14.
- the blow molding assembly further comprises a mold assembly 29, which has internal mold surfaces defining a die cavity.
- the die surfaces correspond to the external surface shape of the part to be blow molded.
- the mold assembly comprises parts capable of relative movement therebetween. More specifically, two mold parts 36 and 37 form side walls of the die cavity, and the base plate 26 forms the bottom wall when the base plate 26 is moved to its lowered position as illustrated in Figure 2.
- the mold assembly 29 starts in the open configuration, as shown in Figure 1.
- the base plate 26 is pressed firmly against the head assembly 14 and closes the latter so that the preform 25 can be formed.
- the movable base plate 26 is then moved downwardly to drop a parison 41 of the hot plastic melt 20 (see Figure 2).
- the ejecting ram mechanism 24 can be thrust forward to assist parison formation.
- the base plate 26 is lowered, while supporting the bottom of the tubular parison 41, and the second mold assembly 29 is closed.
- the amount of plastic melt 20 communicated in the form of tubular parison 41 to the mold assembly is sufficient to form a part having a weight of at least 2 pounds and a total surface area of at least 400 sq. inches, as the present invention is primarily concerned with larger parts of this magnitude. Smaller parts are not benefited vis-a-vis reinforcement to the same extent as larger parts (smaller parts usually do not require the same degree of structural integrity as larger parts).
- the mold assembly 29 is provided with appropriate water cooling lines and a temperature control unit in conventional fashion for regulating the temperature of the mold assembly.
- the plastic melt 20 (and thus the resultant part) comprises at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material.
- the reinforcement particles comprise less than 15% of a total volume of the plastic melt 20, at least 50% of the reinforcement particles have a thickness of less than about 20 nanometers, and at least 99% of the reinforcement particles have a thickness of less than about 30 nanometers.
- a tubular formation in the form of parison 41 of the plastic melt is communicated to the mold assembly 29.
- the mold surfaces 43 correspond to a configuration of the part to be molded.
- Pressurized gas is applied through conduit or port 38 to an interior of the tubular formation 41 to expand the tubular formation into conformity with the mold surfaces 43.
- the plastic melt when forced into conformity with surfaces 43 is then permitted to solidify (e.g, by cooling the mold assembly 29) to form the part 46.
- the solidified part is then removed from the mold assembly 29 and after the mold assembly 29 is opened.
- the reinforcement filler particles also referred to as “nanoparticles” due to the magnitude of their dimensions, each comprise one or more generally flat platelets.
- Each platelet has a thickness of between 0.7-1.2 nanometers.
- thickness is approximately 1 nanometer thick.
- the aspect ratio (which is the largest dimension divided by the thickness) for each particle is about 50 to about 300.
- the platelet particles or nanoparticles are derivable from larger layered mineral particles.
- Any layered mineral capable of being intercalated may be employed in the present invention.
- Layered silicate minerals are preferred.
- the layered silicate minerals that may be employed include natural and artificial minerals.
- Non-limiting examples of more preferred minerals include montmorillonite, vermiculite, hectorite, saponite, hydrotalcites, kanemite, sodium octosilicate, magadite, and kenyaite.
- Mixed Mg and Al hydroxides may also be used.
- montmorillonite is Among the most preferred minerals.
- swellable layered minerals such as montmorillonite and saponite are known to intercalate water to expand the inter layer distance of the layered mineral, thereby facilitating exfoliation and dispersion of the layers uniformly in water. Dispersion of layers in water is aided by mixing with high shear.
- the mineral particles may also be exfoliated by a shearing process in which the mineral particles are impregnated with water, then frozen, and then dried. The freeze dried particles are then mixed into molten polymeric material and subjected to a high sheer mixing operation so as to peel individual platelets from multi-platelet particles and thereby reduce the particle sizes to the desired
- the plastic melt 20 utilized in accordance with the present invention are prepared by combining the platelet mineral with the desired polymer in the desired ratios.
- the components can be blended by general techniques known to those skilled in the art.
- the components can be blended and then melted in mixers or extruders.
- the plastic melt 20 is first manufactured into pellet form. Then pellets are then plasticized in the extruder 1 to form the plastic melt 20..
- the thermoplastic used for the purposes of the present invention is a polyolefin or a blend of polyolefins.
- the preferred polyolefin is at least one member selected from the group consisting of polypropylene, ethylene-propylene copolymers, thermoplastic olefins (TPOs), and thermoplastic polyolefin elastomers (TPEs).
- the exfoliation of layered mineral particles into constituent layers need not be complete in order to achieve the objects of the present invention.
- the present invention contemplates that at least 50% of the particles should be less than about 20 nanometers in thickness and, thus, at least 50% of the particles should be less than about 20 platelets stacked upon one another in the thickness direction.
- at least 99% of the reinforcement particles should have a thickness of less than about 30 nanometers.
- At least 50 % of the particles should have a thickness of less than 10 nanometers. At this level, an additional increase of about 50-70% in the modulus of elasticity is achieved in comparison with the 50% of particles being less than 20 nanometer thick as discussed above. This provides a level of reinforcement and impact resistance that would be highly suitable for most motor vehicle bumper applications.
- At least 70% of the particles should have a thickness of less than 5 nanometers, which would achieve an additional 50-70% increase in the modulus of elasticity in comparison with the 50% of less than 10 nanometer thickness exfoliation discussed above.
- This provides ideal reinforcement and impact resistance for large thin parts that must withstand greater degrees of impart. It is always preferable for at least 99% of the particles to a thickness of less than about 30 nanometers (i.e., less than about 30 layers or platelets thick), as particles greater than this size act as stress concentrators..
- the preferred aspect ratio (which is the largest dimension divided by
- the thickness) for each particle is about 50 to about 300. At least 80% of the particles should be within this range. If too many particles have an aspect ratio above 300, the material becomes too viscous for forming parts in an effective and efficient manner. If too many particles have an aspect ratio of smaller than 50, the particle reinforcements will not provide
- the desired reinforcement characteristics More preferably, the aspect ratio for each particle is between 100-200 . Most preferably, at least 90% of the particles have an aspect ratio within the 100-200 range.
- the plastic melt 20 and hence the
- parts to be manufactured should contain less than 15% by volume of the reinforcement particles of the type contemplated herein.
- the balance of the part is to comprise an appropriate polyolefin material and suitable additives. If greater than 15% by volume of reinforcement filler is used, the viscosity of the composition becomes too high and thus difficult to mold.
- the structure 50 is formed from at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material.
- the reinforcement particles comprise less than 15% of a total volume of the integrally formed radiator and light support structure 50, at least 50% of the reinforcement particles have a thickness of less than about 20 nanometers, and at least 99% of the reinforcement particles have a thickness of less than about 30 nanometers.
- the structure 50 comprises a radiator frame portion 52, having apertures 54 for securing a motor vehicle radiator (not shown for sake of clarity) to the support structure 50.
- a pair of light receiving recesses 56 of the support structure 50 are constructed and arranged to mount headlights (not shown for sake of clarity) for the motor vehicle.
- the recesses 56 having apertures 58 for receiving electrical connecting portions of the lights.
- the support structure can be nestingly received with respect to a motor vehicle fascia, indicated at 60.
- a hollow, sealed front end bumper generally indicated at 70.
- the bumper 70 is shown mounted to the front end of a motor vehicle, generally indicated at 72.
- the hollow bumper comprises at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material.
- the reinforcement particles comprise less than 15% of a total volume of the bumper, at least 50% of the reinforcement particles have a thickness of less than about 20 nanometers, and at least 99% of the reinforcement particles have a
- a fluid consuming component such as a conventional windshield wiper fluid spraying assembly, generally indicated at 74 in FIG. 5, is constructed and arranged to be mounted on and used by the motor vehicle.
- a conduit 76 communicates the fluid consuming component with the sealed interior of the hollow bumper 70, thus permitting said hollow sealed bumper to serve as a fluid reservoir for the fluid consuming component (e.g., the wiper fluid spraying assembly 74).
- the fluid consuming component to which the bumper 70 is communicated may be other components in the motor vehicle as well, such as the radiator 78, which may be communicated with the interior of the bumper 70 by conduit 80 (see FIG. 5).
- the bumper 70 may be divided so as to have two separate compartments.
- the interior of bumper 70 is divided into compartments 84 and 86, with the compartment 84 communicating with the wiper spray assembly 74 via conduit 76, and the compartment
- the assembly 100 is formed from at least one thermoplastic material and reinforcement particles dispersed within the at least one thermoplastic material.
- the reinforcement particles comprise less than 15% of a total volume of the support structure assembly, at least 50% of the reinforcement particles have a thickness of less than about 20 nanometers, and at least 99% of the reinforcement particles having a thickness of less than about 30 nanometers.
- the integrally formed assembly includes i) a hollow radiator frame portion 102, and apertures 104 formed in the frame portion for securing a motor vehicle radiator (not shown for sake of clarity) to the frame portion 102, ii) a pair of light receiving recesses 106 constructed and arranged to mount lights (not shown for sake of clarity of illustration) for the motor vehicle. Apertures 108 are formed in the recesses 106 for connecting the lights with an electrical power source, and iii) a hollow bumper portion 1 10 constructed and arranged to be mounted to a front end of a motor
- the modulus of the material used to form a bumper is increased to between about 200,000 to about 500,000 PSI.
- the modulus of the large, thin part can be increased without
- bumpers for automobiles must have sufficient impact resistance or toughness to withstand various standard automotive impact tests.
- the bumper will not crack or permanently deform upon impact of at least 200 inch pounds force at a temperature of -30°C or lower.
- IZOD impact test it is desirable for the bumper to withstand at least 10 ft pounds/inch at room temperature
- the modulus for the conventional bumper is typically between about 70,000 to about 150,000 pounds per square inch. (PSI). In accordance with the present invention, the modulus can be increased by a factor of 2 to 3 times, without significantly effecting the impact resistance.
- nanoparticle reinforced plastic melt enables the coefficient of linear thermal expansion to be reduced to less than 40 xl0-6 inches of expansion per inch of material per degree Fahrenheit (IN/IN)/ 0 F, which is less than 60% of what was previously achievable for thermoplastic motor vehicle bumpers that meet the required impact tests.
- the surface toughness of the bumper can be improved.
- the improved surface toughness provided by the nanoparticles greatly reduces handling damage and part scrap. It also eliminates the need for the extra packaging and protective materials and the labor involved.
- the use of nanoparticles can provide the mechanical, thermal, and dimensional property enhancements, which are typically
- these parts prefferably have reinforcement particles of the type described herein comprising about 2-10% of the total volume of the panel, with the balance comprising the polyolefin substrate. It is even more preferable for these exterior panels to have reinforcement particles of the type contemplated herein comprising about 3%-5% of the total volume of the panel.
- the blow molding apparatus can be used to make large, highly reinforced parts having a modulus of elasticity of 1 ,000,000 or greater. Conventionally, these parts typically require loadings of 25-40% by volume of glass fiber reinforcement. This amount of glass fiber loading would result in a high viscosity of any melt pool that could be used in the blow molding apparatus of the present invention and would thus render the blow molding apparatus disclosed herein largely impractical for such application.
- plastic melt 20 as described above enables the blow molding apparatus disclosed herein to manufacture large parts that can be provided with impact resistance
- the present invention is able to manufacture large parts having a modulus of elasticity of greater than 1 ,000,000 PSI by use of the plastic melt reinforced with loadings of 8-15% by volume of nanoparticles, with at least 70% of the nanoparticles having a thickness of 10
- the plastic melt used has substantially the same material composition as the part to be manufactured. In this case of molding large parts with a modulus of elasticity greater than 1,000,000
- Such engineering resins may include polycarbonate (PC), acrylonitrile butadiene styrene (ABS), a PC/ABS blend, polyethylene terephthalates (PET), polybutylene terephthalates (PBT), polyphenylene oxide (PPO), or the like.
- PC polycarbonate
- ABS acrylonitrile butadiene styrene
- PET polyethylene terephthalates
- PBT polybutylene terephthalates
- PPO polyphenylene oxide
Abstract
Description
Claims
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US09/857,767 US6988305B1 (en) | 1999-12-17 | 1999-12-17 | Method and apparatus for blow molding large reinforced plastic parts |
CA002355642A CA2355642C (en) | 1998-12-21 | 1999-12-17 | Method and apparatus for blow molding large reinforced plastic parts |
AU23660/00A AU2366000A (en) | 1998-12-21 | 1999-12-17 | Method and apparatus for blow molding large reinforced plastic parts |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US11306498P | 1998-12-21 | 1998-12-21 | |
US60/113,064 | 1998-12-21 |
Publications (2)
Publication Number | Publication Date |
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WO2000037239A1 true WO2000037239A1 (en) | 2000-06-29 |
WO2000037239A9 WO2000037239A9 (en) | 2002-08-22 |
Family
ID=22347426
Family Applications (2)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1999/029991 WO2000037239A1 (en) | 1998-12-21 | 1999-12-17 | Method and apparatus for blow molding large reinforced plastic parts |
PCT/US1999/029987 WO2000037230A1 (en) | 1998-12-21 | 1999-12-17 | Method for vacuum pressure forming reinforced plastic articles |
Family Applications After (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1999/029987 WO2000037230A1 (en) | 1998-12-21 | 1999-12-17 | Method for vacuum pressure forming reinforced plastic articles |
Country Status (3)
Country | Link |
---|---|
AU (2) | AU2365700A (en) |
CA (2) | CA2355642C (en) |
WO (2) | WO2000037239A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102008059322A1 (en) * | 2008-11-27 | 2010-06-02 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | Bumper arrangement for sports car, has reinforcement element connected with lining part, where reinforcement element reinforces lining element mainly during temperature-dependent deformations and pressure loads |
DE102008059323A1 (en) * | 2008-11-27 | 2010-06-02 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | Bumper arrangement for passenger car, has reinforcement element connected with lining element, where reinforcement element has lattice-like structure and retainer formed as single-piece with structure for mounting/fitting illuminant element |
DE102012016035A1 (en) * | 2012-08-13 | 2014-02-13 | Bomag Gmbh | Road construction machine |
Families Citing this family (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
AU2011211400B2 (en) * | 2010-08-12 | 2014-12-04 | Britax Childcare Pty Ltd | Child safety seat reinforcement |
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US4876033A (en) * | 1986-06-10 | 1989-10-24 | Bayer Aktiengesellschaft | Moulded bodies containing carbon |
EP0738580A1 (en) * | 1994-01-11 | 1996-10-23 | Nippon Steel Chemical Co., Ltd. | Multilayered blow molding |
EP0747451A2 (en) * | 1995-06-07 | 1996-12-11 | Amcol International Corporation | Intercalates and exfoliates formed with oligomers and polymers and composite materials containing same |
EP0810260A1 (en) * | 1996-05-28 | 1997-12-03 | Bayer Ag | Films or hollow articles containing a polyamide layer |
EP0810259A1 (en) * | 1996-05-28 | 1997-12-03 | Bayer Ag | Polyamid moulding compositions containing nanodisperse fillers and films or hollow articles containing such polyamid layer |
WO1999061281A1 (en) * | 1998-05-22 | 1999-12-02 | Magna International Of America, Inc. | Exterior panels for motor vehicles |
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US4287143A (en) * | 1979-03-19 | 1981-09-01 | Sears Manufacturing Company | Cloth molding process |
JPH06510247A (en) * | 1991-09-06 | 1994-11-17 | ザ・ダウ・ケミカル・カンパニー | Insulating plastic composite structure |
US5849830A (en) * | 1995-06-07 | 1998-12-15 | Amcol International Corporation | Intercalates and exfoliates formed with N-alkenyl amides and/or acrylate-functional pyrrolidone and allylic monomers, oligomers and copolymers and composite materials containing same |
JP2000505491A (en) * | 1996-02-23 | 2000-05-09 | ザ・ダウ・ケミカル・カンパニー | Dispersion with delamination particles in polymer foam |
-
1999
- 1999-12-17 AU AU23657/00A patent/AU2365700A/en not_active Abandoned
- 1999-12-17 AU AU23660/00A patent/AU2366000A/en not_active Abandoned
- 1999-12-17 CA CA002355642A patent/CA2355642C/en not_active Expired - Fee Related
- 1999-12-17 WO PCT/US1999/029991 patent/WO2000037239A1/en active Application Filing
- 1999-12-17 CA CA002355641A patent/CA2355641C/en not_active Expired - Fee Related
- 1999-12-17 WO PCT/US1999/029987 patent/WO2000037230A1/en active Application Filing
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US4876033A (en) * | 1986-06-10 | 1989-10-24 | Bayer Aktiengesellschaft | Moulded bodies containing carbon |
EP0738580A1 (en) * | 1994-01-11 | 1996-10-23 | Nippon Steel Chemical Co., Ltd. | Multilayered blow molding |
EP0747451A2 (en) * | 1995-06-07 | 1996-12-11 | Amcol International Corporation | Intercalates and exfoliates formed with oligomers and polymers and composite materials containing same |
EP0810260A1 (en) * | 1996-05-28 | 1997-12-03 | Bayer Ag | Films or hollow articles containing a polyamide layer |
EP0810259A1 (en) * | 1996-05-28 | 1997-12-03 | Bayer Ag | Polyamid moulding compositions containing nanodisperse fillers and films or hollow articles containing such polyamid layer |
WO1999061281A1 (en) * | 1998-05-22 | 1999-12-02 | Magna International Of America, Inc. | Exterior panels for motor vehicles |
Cited By (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102008059322A1 (en) * | 2008-11-27 | 2010-06-02 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | Bumper arrangement for sports car, has reinforcement element connected with lining part, where reinforcement element reinforces lining element mainly during temperature-dependent deformations and pressure loads |
DE102008059323A1 (en) * | 2008-11-27 | 2010-06-02 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | Bumper arrangement for passenger car, has reinforcement element connected with lining element, where reinforcement element has lattice-like structure and retainer formed as single-piece with structure for mounting/fitting illuminant element |
DE102008059322B4 (en) * | 2008-11-27 | 2019-10-10 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | bumper assembly |
DE102008059323B4 (en) | 2008-11-27 | 2023-06-07 | Dr. Ing. H.C. F. Porsche Aktiengesellschaft | bumper assembly |
DE102012016035A1 (en) * | 2012-08-13 | 2014-02-13 | Bomag Gmbh | Road construction machine |
Also Published As
Publication number | Publication date |
---|---|
WO2000037230A1 (en) | 2000-06-29 |
CA2355641C (en) | 2008-07-15 |
CA2355642C (en) | 2006-05-16 |
AU2366000A (en) | 2000-07-12 |
CA2355642A1 (en) | 2000-06-29 |
CA2355641A1 (en) | 2000-06-29 |
WO2000037239A9 (en) | 2002-08-22 |
AU2365700A (en) | 2000-07-12 |
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