WO2020160758A1 - Piece made of two fibre reinforced thermoplastic parts and method for making the same - Google Patents

Piece made of two fibre reinforced thermoplastic parts and method for making the same Download PDF

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Publication number
WO2020160758A1
WO2020160758A1 PCT/EP2019/052783 EP2019052783W WO2020160758A1 WO 2020160758 A1 WO2020160758 A1 WO 2020160758A1 EP 2019052783 W EP2019052783 W EP 2019052783W WO 2020160758 A1 WO2020160758 A1 WO 2020160758A1
Authority
WO
WIPO (PCT)
Prior art keywords
interlocking connection
protrusions
recesses
sheet
piece
Prior art date
Application number
PCT/EP2019/052783
Other languages
French (fr)
Inventor
Martin Kerschbaum
Julien TACHON
Original Assignee
Toyota Motor Europe
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 Toyota Motor Europe filed Critical Toyota Motor Europe
Priority to PCT/EP2019/052783 priority Critical patent/WO2020160758A1/en
Priority to DE112019006819.9T priority patent/DE112019006819T5/en
Publication of WO2020160758A1 publication Critical patent/WO2020160758A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0014—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with ridges or ribs, e.g. joined ribs
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14467—Joining articles or parts of a single article
    • B29C45/14508—Joining juxtaposed sheet-like articles, e.g. for making trim panels
    • 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
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14778—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the article consisting of a material with particular properties, e.g. porous, brittle
    • B29C45/14786—Fibrous material or fibre containing material, e.g. fibre mats or fibre reinforced 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/4805—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding characterised by the type of adhesives
    • B29C65/481—Non-reactive adhesives, e.g. physically hardening adhesives
    • B29C65/4815—Hot melt adhesives, e.g. thermoplastic adhesives
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5007—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like
    • B29C65/5014—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like characterised by the structure of said adhesive tape, threads or the like being fibre-reinforced
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/48—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding
    • B29C65/50—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like
    • B29C65/5042—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using adhesives, i.e. using supplementary joining material; solvent bonding using adhesive tape, e.g. thermoplastic tape; using threads or the like covering both elements to be joined
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
    • B29C65/564—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined hidden in the joint, e.g. dowels or Z-pins
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/62—Stitching
    • 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
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/72—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by combined operations or combined techniques, e.g. welding and stitching
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/03—After-treatments in the joint area
    • B29C66/038—Covering the joint by a coating material
    • B29C66/0384—Covering the joint by a coating material the coating material being in tape, strip or band form
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/114—Single butt joints
    • B29C66/1142—Single butt to butt joints
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/22—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns
    • B29C66/227—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns being in the form of repetitive interlocking undercuts, e.g. in the form of puzzle cuts
    • B29C66/2272—Teardrop-like, waterdrop-like or mushroom-like interlocking undercuts
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/22—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns
    • B29C66/227—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns being in the form of repetitive interlocking undercuts, e.g. in the form of puzzle cuts
    • B29C66/2274—Dovetailed interlocking undercuts
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/20—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines
    • B29C66/22—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns
    • B29C66/227—Particular design of joint configurations particular design of the joint lines, e.g. of the weld lines said joint lines being in the form of recurring patterns being in the form of repetitive interlocking undercuts, e.g. in the form of puzzle cuts
    • B29C66/2276—Other specific local geometries of interlocking undercuts not provided for in B29C66/2272 - B29C66/2274
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/7392—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic
    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
    • 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
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/001—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore a shaping technique combined with cutting, e.g. in parts or slices combined with rearranging and joining the cut parts
    • 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
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/304—In-plane lamination by juxtaposing or interleaving of plies, e.g. scarf joining
    • 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
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    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
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    • B29C70/465—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 by melting a solid material, e.g. sheets, powders of fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
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    • B29C70/845—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by moulding material on preformed parts to be joined by moulding material on a relative small portion of the preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C2793/00—Shaping techniques involving a cutting or machining operation
    • B29C2793/0072—Shaping techniques involving a cutting or machining operation combined with rearranging and joining the cut parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
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    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/71—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined
    • B29C66/712—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the composition of the plastics material of the parts to be joined the composition of one of the parts to be joined being different from the composition of the other part
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7212—Fibre-reinforced materials characterised by the composition of the fibres
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72141—Fibres of continuous length
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B29C66/7214—Fibre-reinforced materials characterised by the length of the fibres
    • B29C66/72143—Fibres of discontinuous lengths
    • 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
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/735—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the extensive physical properties of the parts to be joined
    • B29C66/7352—Thickness, e.g. very thin

Definitions

  • the present disclosure is related to piece made of fibre reinforced thermoplastic, and more particularly to a piece made of at least two fibre reinforced thermoplastic parts.
  • the piece When making a piece of fibre reinforced thermoplastic, the piece may be cut from a flat sheet of fibre reinforced thermoplastic. The piece may then be formed in a 3D-form and then overmoulded with polymer.
  • a non-negligible part of the sheet may be wasted.
  • a plurality of pieces 202 are cut from a sheet 200 of fibre reinforced thermoplastic. It can be seen that a non-negligible part of the sheet 200 is not used and is discarded as waste.
  • a piece includes a first part made of fibre reinforced thermoplastic and including a first connecting edge made by alternating first protrusions and first recesses, and a second part made of fibre reinforced thermoplastic and including a second connecting edge made by alternating second protrusions and second recesses, the first protrusions being complementary to the second recesses and being received in the second recesses and the second protrusions being complementary to the first recesses and being received in the first recesses, the first protrusions, first recesses, second protrusions and second recesses forming an interlocking connection between the first part and the second part against at least compressive and shear forces occurring in the interlocking connection plane when the first part and the second part are flat, the interlocking connection being overmoulded with a polymer.
  • first part and the second part are flat, i.e., not formed in a 3-D shape, they substantially define a plane, which is the interlocking connection plane.
  • Compression forces are understood as being forces that push the first part towards the second part in a direction substantially perpendicular to the general interlocking connection direction, while shear forces are forces that are exerted in the plane in a direction substantially parallel to the general interlocking connection direction.
  • the polymer may be a thermoplastic or a thermosetting polymer.
  • the polymer may be reinforced with fibres. For injection moulding, fibres are generally short.
  • Non-limiting examples of polymer are short glass reinforced polypropylene, polyamide, acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyphthalamide (PPA), polyether ether ketone (PEEK), epoxy (EP), polyurethane (PU).
  • ABS acrylonitrile butadiene styrene
  • PC polycarbonate
  • PBT polybutylene terephthalate
  • PET polyethylene terephthalate
  • PPA polyphthalamide
  • PEEK polyether ether ketone
  • EP epoxy
  • PU polyurethane
  • the polymer may also be overmoulded on parts of the first and second parts that are different from the interlocking connection, i.e., the polymer is overmoulded both on the interlocking connection and parts of the first and second parts that are different from the interlocking connection.
  • the first part and the second part may be cut from a same sheet of fibre reinforced thermoplastic.
  • the fibre reinforced thermoplastic may be continuous fibre reinforced thermoplastic or discontinuous fibre reinforced thermoplastic.
  • the fibres may be non-woven mats, woven fabrics, non-crimp fabrics or unidirectional layers of arbitrary direction.
  • Non-limiting examples of fibres include glass fibres, carbon fibres, aramid fibres, natural fibres.
  • Non-limiting examples of thermoplastic include polypropylene, polyamide, acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyphthalamide (PPA), polyether ether ketone (PEEK), epoxy (EP), polyurethane (PU)
  • the sheet of fibre reinforced thermoplastic may have a thickness equal to or larger than 1 mm (millimetre), preferably equal to or larger than
  • the first part and the second part may be cut from different sheets of fibre reinforced thermoplastic.
  • the first sheet and the second sheet of fibre reinforced thermoplastic may be made of different fibre reinforced thermoplastic.
  • the first part and the second part are made of different fibre reinforced thermoplastic.
  • the first sheet and the second sheet of fibre reinforced thermoplastic may be different sheets of the same fibre reinforced thermoplastic.
  • the first part and the second part may be cut in different sheets.
  • the piece may include more than two parts assembled to one another using an interlocking connection.
  • the piece may include three parts made of fibre reinforced thermoplastic and including a first connecting edge made by alternating first protrusions and first recesses, i.e., a first part, a second part and a third part.
  • the piece may include more than three parts.
  • the interlocking connection between the first part and the second part is against tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
  • Tensile forces are understood as being forces that pull apart the first part and the second part in a direction substantially perpendicular to the general interlocking connection direction.
  • staples are disposed along the interlocking connection, each staple having a first leg into the first part and a second leg into the second part.
  • the staples may be metallic staples or plastic staples.
  • a staple has two legs linked by a crown. Each staple has a first leg passing through the first part and folded over the first part and a second leg passing through the second part and folded over the second part, the crown thus crossing the interlocking connection.
  • a sheet of fibres is at least partially impregnated by the thermoplastic material of both the first part and the second part, the sheet covering the interlocking connection.
  • the external surface of the sheet of fibres is flush with the surface of the first part and the second part.
  • the sheet of fibres does not add an extra thickness to the first and second parts.
  • the sheet of fibres may be a non-woven mat, a woven fabric, a noncrimp fabric.
  • the sheet of fibres may include a binder.
  • the fibres of the sheet of fibres may be of the same as the fibres of the first part and/or the second part.
  • the sheet of fibres may have a thickness equal to or larger than 0,10 mm (millimetre), preferably equal to or larger than 0,15 mm and equal to or smaller than 0,50 mm, preferably equal to or smaller than 0,45 mm.
  • the sheet is a first sheet and a second sheet of fibres is at least partially impregnated by the thermoplastic material of both the first part and the second part, the second sheet covering the interlocking connection, so that both sides of the interlocking connection are covered.
  • the sheet of fibres is a sheet of fibre reinforced thermoplastic.
  • thermoplastic may be the same as the thermoplastic of the first part and/or the second part.
  • the first part is stitched to the second part at the interlocking connection.
  • the first protrusions and the second protrusions have the same shape and dimensions.
  • first recesses being complementary to the second protrusions and the second recesses being complementary to the first protrusions, it is understood that the first recesses and the second recesses have the same shape and dimensions.
  • the first protrusions, the first recesses, the second protrusions and the second recesses have a dovetail shape.
  • the interlocking connection between the first part and the second part is against compressive, shear and tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
  • the first protrusions, the first recesses, the second protrusions and the second recesses have a "T" shape.
  • the interlocking connection between the first part and the second part is against compressive, shear and tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
  • the first protrusions, the first recesses, the second protrusions and the second recesses have a crenelated shape.
  • the interlocking connection between the first part and the second part is against compressive and shear forces occurring in the interlocking connection plane when the first part and the second part are flat.
  • the first protrusions and the second protrusions have different shapes and dimensions.
  • All the first protrusions may have the same shape and dimensions and all the second protrusions may have the same shape and dimensions, while the shape and dimensions of the first protrusions may differ from the shape and dimensions of the second protrusions.
  • all first recesses have the same shape and dimensions and all the second recesses have the same shape and dimensions, the first recesses being complementary to the second protrusions and the second recesses being complementary to the first protrusions.
  • the first protrusions may have a shape of a mushroom, while the second protrusions have the complementary shape of the first recesses which are delimited by the first protrusions.
  • the interlocking connection between the first part and the second part is against compressive, shear and tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
  • the first protrusions may have different shapes and dimensions, at least one first protrusion having a different shape and dimensions relative to the other first protrusions and the second protrusions may have different shapes and dimensions, at least one second protrusion having a different shape and dimensions relative to the other second protrusions.
  • the interlocking connection between the first part and the second part is against compressive and shear forces occurring in the interlocking connection plane when the first part and the second part are flat.
  • a method for making a piece by assembling a first part made of fibre reinforced thermoplastic and a second part made of fibre reinforced thermoplastic is provided.
  • the method includes:
  • first part in a first sheet of fibre reinforced thermoplastic
  • first part comprising a first connecting edge made by alternating first protrusions and first recesses and cutting the second part in the first sheet or in a second sheet of fibre reinforced thermoplastic
  • second part comprising a second connecting edge made by alternating second protrusions and second recesses, the first protrusions being complementary to the second recesses and the second protrusions being complementary to the first recesses;
  • the overmoulding may include a cooling step.
  • the heating step may be carried out in an infrared oven.
  • the heating temperature is between the glass transition temperature and the melting temperature of the thermoplastic.
  • the interlocking connection between the first part and the second part is against tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
  • the method includes a step of reinforcing the interlocking connection.
  • Reinforcement of the interlocking connection may help stabilizing the interlocking connection during handling of assembly and may prevent misalignment of the two parts in the shaping mould, as the parts are softened and more deformable than at room temperature.
  • the step of reinforcing the interlocking connection is carried out between the assembling step and the heating step.
  • the step of reinforcing the interlocking connection comprises stapling the interlocking connection with hot staples, each staple having a first leg into the first part and a second leg into the second part.
  • hot staples allows carrying out the reinforcing step without warming up the first and the second part. Indeed, the hot staples soften the thermoplastic during penetration of the legs of the staples into the thermoplastic.
  • the staples may be made of metallic alloys, such as steel.
  • the staples may be made of polymer, such as polyamide.
  • the step of reinforcing the interlocking connection comprises hot pressing a sheet of fibres on the interlocking connection.
  • the sheet of fibres may improve guiding the injected thermoplastic during the overmoulding step.
  • the step of reinforcing the interlocking connection comprises hot pressing a sheet of fibres on each side of the interlocking connection.
  • the step of reinforcing the interlocking connection is carried out during the heating step.
  • the step of reinforcing the interlocking connection comprises stapling the interlocking connection with staples, each staple having a first leg into the first part and a second leg into the second part.
  • thermoplastic of the first part and the second part is softened and the legs of the staples may penetrate into the thermoplastic.
  • the staples may be made of metallic alloys, such as steel, or of polymer such as polyamide.
  • the step of reinforcing the interlocking connection comprises stitching the first part to the second part at the interlocking connection.
  • Stitching material may be a yarn, for example a polyester yarn, a polyamide yarn, etc.
  • Fig. 1 shows a representation of a sheet of fibre reinforced thermoplastic showing known cutting
  • Fig. 2 shows a representation of an exemplary piece according to embodiments of the present disclosure
  • Fig. 3 shows a representation of an exemplary sheet of fibre reinforced thermoplastic showing cutting according to embodiments of the present disclosure
  • Fig. 4 shows a representation of an exemplary first part and second part according to embodiments of the present disclosure
  • Fig. 5 shows a representation of an exemplary assembly according to embodiments of the present disclosure
  • Fig. 6 shows a representation of an exemplary formed assembly according to embodiments of the present disclosure
  • Fig. 7 shows a schematic representation of an enlargement Fig. 4;
  • Fig. 8 shows the parts of Fig. 7 during assembly
  • Fig. 9 shows the parts of Fig. 7 after assembly
  • Fig. 10 shows the parts of Fig. 7 after overmoulding
  • FIGS. 11-14 show enlargements of other exemplary assemblies according to embodiments of the present disclosure.
  • Fig. 15 shows the step of overmoulding according to embodiments of the present disclosure
  • Figs. 16A-16C show the covering of the interlocking connection with two sheets of fibres according to embodiments of the present disclosure
  • FIG. 17 shows a representation of an exemplary assembly with reinforced interlocking connection according to embodiments of the present disclosure
  • Figs. 18 and 19 show other exemplary assemblies with reinforced interlocking connection according to embodiments of the present disclosure.
  • Fig. 20 shows a flow chart of the method according to embodiments of the present disclosure.
  • Fig. 2 shows a representation of an exemplary piece 10 according to embodiments of the present disclosure.
  • the piece 10 includes a first part 12 and a second part 14, each made of fibre reinforced thermoplastic, the first part 12 and the second part 14 being overmoulded with a polymer 16.
  • Fig. 20 shows a flow chart of a method 100 for making the piece 10 according to embodiments of the present disclosure.
  • the method includes a step 102 of cutting the first part 12 and the second part 14 in a sheet 18 of fibre reinforced thermoplastic.
  • first part 12 and the second part 14 may be cut from the same sheet 18 of fibre reinforced thermoplastic.
  • the first part 12 and the second part 14 may be cut from two different sheets 18.
  • the sheet of fibre reinforced thermoplastic may be continuous glass fibre reinforced polypropylene having a thickness 20A of 2 mm (see Fig. 15).
  • glass fibre reinforced polypropylene such as Lanxess Tepex® dynalite 104-RG600(2)-RGUDm317(4)/48% black Typ S) with a (0/90/- 45/+45)s layup may be used.
  • the first part 12 includes a first connecting edge 12A and the second part 14 includes a second connecting edge 14A.
  • the first part 12 and the second part 14 are assembled together along the first and second connecting edges 12A, 14A.
  • the assembled the first and second connecting edges 12A, 14A forms an interlocking connection 22 between the first part 12 and the second part 14.
  • the assembly 20 is flat and has the thickness of the sheet 18 in which the first part 12 and the second part 14 have been cut.
  • the interlocking connection 22 acts in keeping the first part 12 and the second part 14 together against at least compressive C and shear S forces that may occur in the interlocking connection plane when the first part 12 and the second part 14 are flat, i.e., as represented at Fig. 5.
  • the assembly 20 is heated so as to obtain a softened assembly, i.e., an assembly at which temperature the thermoplastic is softened and can be deformed without breaking.
  • the heating step 106 may be carried out in an infrared oven between the glass transition temperature and the melting temperature of the thermoplastic.
  • the softened assembly is then placed in a shaping mould 120 (see Fig. 15) to give the softened assembly the desired form, thus obtaining a formed assembly 24, as represented at Fig. 6.
  • the formed assembly 24 is formed by the softened assembly being pushed against a lower part 120B of the shaping mold 120.
  • the mold 120 then closes and an upper part 120A of the shaping mold 120 may touch the softened assembly and form it.
  • the overmoulding of the formed assembly 24 may take place during overmoulding step 110.
  • step 110 as shown at Fig. 6, the formed assembly 24 rest against the lower part 120B of the shaping mould 120 and polymer 16 is injected into cavities 120C of the shaping mould 120 present between the formed assembly 24 and the upper part 120A of the shaping mould 120, so that the polymer 16 finally pushes the formed assembly 24 against the lower part 120B which gives the final shape.
  • the piece 10 is obtained.
  • the polymer 16 is a thermoplastic polymer
  • the polymer hardened by lowering the temperature of the polymer.
  • the polymer 16 is a thermosetting polymer, the polymer is cured.
  • the method 100 may be applied to first and second parts 12, 14 having first and second connecting edges 12A, 14A, made by alternating protrusions and recesses having the same shape and dimensions.
  • first protrusions 12B and first recesses 12C when cutting the first part 12, one cuts the first connecting edge 12A, which is made by alternating first protrusions 12B and first recesses 12C. In the non-limiting example of Fig. 7, the first protrusions 12B and the first recesses 12C have a dovetail shape.
  • second part 14 when cutting the second part 14, one cuts the second connecting edge 14A, which is made by alternating second protrusions 14B and second recesses 14C. In the nonlimiting example of Fig. 7, the second protrusions 14B and the second recesses 14C have a dovetail shape.
  • the first protrusions 12B have shape complementary to the shape of the second recesses 14C and the second protrusions 14B have shape complementary to the shape of the first recesses 12C.
  • the assembly of the first part 12 to the second part 14 is made by interlocking the first connecting edge 12A and the second connecting edge 14A by receiving the first protrusions 12B in the second recesses 14C and the second protrusions 14B in the first recesses 14B, so as to form the interlocking connection 22 between the first part 12 and the second part 14.
  • the first protrusions 12B, first recesses 12C, second protrusions 14B and second recesses 14C are forming the interlocking connection 22 between the first part 12 and the second part 14.
  • the interlocking connection 22 between the first part 12 and the second part 12 is against compressive C, shear S and tensile T forces occurring in the interlocking connection plane when the first part 12 and the second part 14 are flat.
  • Figs. 11-14 are similar to Fig. 9. Fig. 11-14 are representations of other exemplary assemblies according to embodiments of the present disclosure.
  • the assembly 20 of Fig. 11 differs from the assembly 20 of Fig. 9 in that the first protrusions 12B, the first recesses 12C, the second protrusions 12C and the second recesses 12C have a "T" shape.
  • First and second parts 12, 14 having first and second connecting edges 12A, 14A, are made by alternating protrusions and recesses having the same shape and dimensions.
  • the assembly 20 of Fig. 12 differs from the assembly 20 of Fig. 9 in that the first protrusions 12B have a mushroom shape, i.e., each first protrusion 12B has a stem 12BA and a head 12BB.
  • the second protrusions 14B have a shape complementary to the shape of the first recesses 12C, which are delimited by two consecutive protrusions 12B.
  • all the first protrusions 12B have the same shape and dimensions
  • all the second protrusions 14B have the same shape and dimensions
  • the first protrusions 12B and the second protrusions 14B have different shape and dimensions.
  • the assembly 20 of Fig. 13 differs from the assembly 20 of Fig. 9 in that the first connecting edge 12A and the second connecting edge 12B have a crenelated shape, i.e., the first protrusions 12B, the first recesses 12C, the second protrusions 12C and the second recesses 12C have a crenelated shape.
  • the first protrusions 12B, the first recesses 12C, the second protrusions 12C and the second recesses 12C have the same shape and dimensions.
  • the assembly 20 of Fig. 14 differs from the assembly 20 of Fig. 9 in that the first protrusions 12BA have different shape and dimensions from first protrusions 12BB.
  • the second protrusions 14B have a shape complementary to the shape of the first recesses 12C, which are delimited by two consecutive protrusions 12B.
  • the first protrusions 12B have different shape and dimensions
  • the second protrusions 14B have different shape and dimensions
  • the first protrusions 12B and the second protrusions 14B have different shape and dimensions.
  • Figs. 17-19 are representation of exemplary reinforced interlocking connections 22.
  • the interlocking connection 22 is covered by a sheet 26 of fibres which is impregnated by the thermoplastic material of both the first part 12 and the second part 14.
  • a continuous glass fiber reinforced polypropylene UD tape material (Sabic UDmax GPP 45-70) may be used.
  • the external surface of the sheet 26 of fibres is flush with the surface of the first part 12 and the second part 14.
  • the sheet 26 of fibres does not add an extra thickness to the first and second parts 12, 14.
  • Glass, carbon, aramid or natural fiber may be used.
  • Non- woven for example glass fiber non-woven with an areal weight of 34 g/m 2 and a thickness (non-woven only of 0,29 mm) or glass fiber UD tape with a thickness of 0,25 mm, fiber content of 45 vol-% and polypropylene matrix may be used.
  • the sheet 26 of fibres is applied on one side of the interlocking connection 22.
  • the sheet 26 of fibres may cover both sides of the interlocking connection 22.
  • the step 112 of reinforcing the interlocking connection 22 may take place between the assembling step 104 and the heating step 106.
  • the sheet(s) 26 of fibres may be hot pressed on the assembly 20 before heating.
  • the thickness 26A of the sheet 26 of fibres is small compared to the thickness 20A of the assembly 20.
  • the thickness 26A may be equal to 0,2 mm.
  • the assembly 20 and the sheet(s) 26 of fibres are placed in the cavity of a hot press 140 between an upper plate 140A and a lower plate 140B, the sheet(s) 26 of fibres being disposed on the upper plate 140A and/or the lower plate 140B so as cover the interlocking connection 22 when the reinforcing step 112 is finished.
  • the sheet(s) 26 of fibres may be attached to the upper plate 140A and/or the lower plate 140B by vacuum holders.
  • the upper and lower plates 140A, 140B are heated and bring close to one another so as to press the sheet(s) 26 of fibres into the assembly 20.
  • thermoplastic of the assembly 20 partially melts and penetrates into the sheet(s) 26 of fibres, the thermoplastic being present between the fibres of the sheet(s) 26 of fibres.
  • the sheet(s) is/are thus impregnated, at least partially, with the thermoplastic material of the assembly 20.
  • the upper plate 140A and the lower plate 140B may be further bring closer to one another and the sheet(s) 26 of fibres are further pushed towards and in the assembly 20 so as to form a surface that is flush with the surface of the assembly 20.
  • the interlocking connection 22 may be reinforced with staples 28 disposed along the interlocking connection 22, each staple 28 including a first leg 28A and a second leg 28B linked together by a crown 28C.
  • Each staple 28 has the first leg 28A passing through the first part 12 and folded over the first part 12 and the second leg 28B passing through the second part 14 and folded over the second part 14, the crown 28C thus crossing the interlocking connection 22.
  • the reinforcing step 112 may be carried out either between the assembling step 104 and the heating step 106 or during the heating step 106.
  • the stapes 28 be heated.
  • the use of hot staples 28 allows carrying out the reinforcing step 112 without warming up the first and the second parts 12, 14. Indeed, the hot staples 28 soften the thermoplastic during penetration of the legs 28A, 28B of the staples 28 into the thermoplastic.
  • the staples may be made of metallic alloys, such as steel, or of polymer such as polyamide.
  • the staples 28 need not be heated.
  • the thermoplastic of the first part 12 and the second part 14 is softened and the legs 28A, 28B of the staples 28 may penetrate into the thermoplastic.
  • the staples may be made of metallic alloys or of polymer.
  • the interlocking connection 22 may be reinforced by stitching the first part 12 to the second part 14 at the interlocking connection 22.
  • thermoplastic of the first part 12 and the second part 14 is softened and the first part 12 may be stitched to the second part 14 at the interlocking connection 22.

Abstract

A piece (10) comprising a first part (12) made of fibre reinforced thermoplastic and comprising a first connecting edge made by alternating first protrusions and first recesses, and a second part (14) made of fibre reinforced thermoplastic and comprising a second connecting edge made by alternating second protrusions and second recesses, the first protrusions being complementary to the second recesses and being received in the second recesses and the second protrusions being complementary to the first recesses and being received in the first recesses, the first protrusions, first recesses, second protrusions and second recesses forming an interlocking connection between the first part and the second part against at least compressive and shear forces occurring in the interlocking connection plane when the first part (12) and the second part (14) are flat, the interlocking connection being overmoulded with a polymer (16). A method for making the same.

Description

PIECE MADE OF TWO FIBRE REINFORCED THERMOPLASTIC PARTS AND METHOD FOR MAKING THE SAME
TECHNICAL FIELD
[0001] The present disclosure is related to piece made of fibre reinforced thermoplastic, and more particularly to a piece made of at least two fibre reinforced thermoplastic parts.
BACKGROUND
[0002] When making a piece of fibre reinforced thermoplastic, the piece may be cut from a flat sheet of fibre reinforced thermoplastic. The piece may then be formed in a 3D-form and then overmoulded with polymer.
[0003] Generally, more than one piece is cut from a single sheet of fibre reinforced thermoplastic.
[0004] However, depending on the shape of the piece, a non-negligible part of the sheet may be wasted. For example, as shown at Fig. 1, a plurality of pieces 202 are cut from a sheet 200 of fibre reinforced thermoplastic. It can be seen that a non-negligible part of the sheet 200 is not used and is discarded as waste.
SUMMARY
[0005] Currently, it remains desirable to provide a piece made of fibre reinforced thermoplastic with better use of the sheet of fibre reinforced thermoplastic.
[0006] Therefore, according to embodiments of the present disclosure, a piece is provided. The piece includes a first part made of fibre reinforced thermoplastic and including a first connecting edge made by alternating first protrusions and first recesses, and a second part made of fibre reinforced thermoplastic and including a second connecting edge made by alternating second protrusions and second recesses, the first protrusions being complementary to the second recesses and being received in the second recesses and the second protrusions being complementary to the first recesses and being received in the first recesses, the first protrusions, first recesses, second protrusions and second recesses forming an interlocking connection between the first part and the second part against at least compressive and shear forces occurring in the interlocking connection plane when the first part and the second part are flat, the interlocking connection being overmoulded with a polymer.
[0007] By providing such a configuration, it is possible to make better use of the sheet of fibre reinforced thermoplastic and reduce the part of the sheet that is discarded as waste material.
[0008] It is also possible to obtain a piece made of two fibre reinforced thermoplastic parts assembled together by an interlocking connection. Therefore, adhesive is not needed to assemble the two parts together. Indeed, assembling two such parts with adhesive may be carried out by preparing the surfaces of the parts that have to be joined, applying an adhesive on the surfaces to be joined, fixing the parts to one another and curing the adhesive. These steps are time and cost consuming.
[0009] Moreover, thanks to the interlocking connection obtained by the complementary shapes of respectively the first protrusions and the second recesses and the second protrusions and the first recesses, a good positioning of the two parts relative to one another may be obtained with a mechanical interlocking of the first part and the second part without additional weight.
[0010] When the first part and the second part are flat, i.e., not formed in a 3-D shape, they substantially define a plane, which is the interlocking connection plane. Compression forces are understood as being forces that push the first part towards the second part in a direction substantially perpendicular to the general interlocking connection direction, while shear forces are forces that are exerted in the plane in a direction substantially parallel to the general interlocking connection direction.
[0011] As the first connecting edge is made by alternating first protrusions and first recesses, two consecutive first protrusions delimit one first recess. Likewise, two consecutive first recesses delimit one first protrusion. As the second connecting edge is made by alternating second protrusions and second recesses, two consecutive second protrusions delimit one second recess. Likewise, two consecutive second recesses delimit one second protrusion. [0012] The polymer may be a thermoplastic or a thermosetting polymer. The polymer may be reinforced with fibres. For injection moulding, fibres are generally short. Non-limiting examples of polymer are short glass reinforced polypropylene, polyamide, acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyphthalamide (PPA), polyether ether ketone (PEEK), epoxy (EP), polyurethane (PU).
[0013] The polymer may also be overmoulded on parts of the first and second parts that are different from the interlocking connection, i.e., the polymer is overmoulded both on the interlocking connection and parts of the first and second parts that are different from the interlocking connection.
[0014] In some embodiments, the first part and the second part may be cut from a same sheet of fibre reinforced thermoplastic.
[0015] The fibre reinforced thermoplastic may be continuous fibre reinforced thermoplastic or discontinuous fibre reinforced thermoplastic. The fibres may be non-woven mats, woven fabrics, non-crimp fabrics or unidirectional layers of arbitrary direction. Non-limiting examples of fibres include glass fibres, carbon fibres, aramid fibres, natural fibres. Non-limiting examples of thermoplastic include polypropylene, polyamide, acrylonitrile butadiene styrene (ABS), polycarbonate (PC), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyphthalamide (PPA), polyether ether ketone (PEEK), epoxy (EP), polyurethane (PU)
[0016] The sheet of fibre reinforced thermoplastic may have a thickness equal to or larger than 1 mm (millimetre), preferably equal to or larger than
1.5 mm and equal to or smaller than 5 mm, preferably equal to or smaller than
4.5 mm.
[0017] In some embodiments, the first part and the second part may be cut from different sheets of fibre reinforced thermoplastic.
[0018] The first sheet and the second sheet of fibre reinforced thermoplastic may be made of different fibre reinforced thermoplastic.
[0019] Thus, the first part and the second part are made of different fibre reinforced thermoplastic.
[0020] The first sheet and the second sheet of fibre reinforced thermoplastic may be different sheets of the same fibre reinforced thermoplastic. [0021] Although made of the same fibre reinforced thermoplastic, the first part and the second part may be cut in different sheets.
[0022] The piece may include more than two parts assembled to one another using an interlocking connection. The piece may include three parts made of fibre reinforced thermoplastic and including a first connecting edge made by alternating first protrusions and first recesses, i.e., a first part, a second part and a third part. The piece may include more than three parts.
[0023] According to some embodiments, the interlocking connection between the first part and the second part is against tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
[0024] Tensile forces are understood as being forces that pull apart the first part and the second part in a direction substantially perpendicular to the general interlocking connection direction.
[0025] According to some embodiments, staples are disposed along the interlocking connection, each staple having a first leg into the first part and a second leg into the second part.
[0026] The staples may be metallic staples or plastic staples. A staple has two legs linked by a crown. Each staple has a first leg passing through the first part and folded over the first part and a second leg passing through the second part and folded over the second part, the crown thus crossing the interlocking connection.
[0027] According to some embodiments, a sheet of fibres is at least partially impregnated by the thermoplastic material of both the first part and the second part, the sheet covering the interlocking connection.
[0028] The external surface of the sheet of fibres is flush with the surface of the first part and the second part. The sheet of fibres does not add an extra thickness to the first and second parts.
[0029] The sheet of fibres may be a non-woven mat, a woven fabric, a noncrimp fabric. The sheet of fibres may include a binder.
[0030] The fibres of the sheet of fibres may be of the same as the fibres of the first part and/or the second part.
[0031] The sheet of fibres may have a thickness equal to or larger than 0,10 mm (millimetre), preferably equal to or larger than 0,15 mm and equal to or smaller than 0,50 mm, preferably equal to or smaller than 0,45 mm. [0032] According to some embodiments, the sheet is a first sheet and a second sheet of fibres is at least partially impregnated by the thermoplastic material of both the first part and the second part, the second sheet covering the interlocking connection, so that both sides of the interlocking connection are covered.
[0033] According to some embodiments, the sheet of fibres is a sheet of fibre reinforced thermoplastic.
[0034] The thermoplastic may be the same as the thermoplastic of the first part and/or the second part.
[0035] According to some embodiments, the first part is stitched to the second part at the interlocking connection.
[0036] According to some embodiments, the first protrusions and the second protrusions have the same shape and dimensions.
[0037] The first recesses being complementary to the second protrusions and the second recesses being complementary to the first protrusions, it is understood that the first recesses and the second recesses have the same shape and dimensions.
[0038] According to some embodiments, the first protrusions, the first recesses, the second protrusions and the second recesses have a dovetail shape.
[0039] With such a configuration of the protrusions and the recesses, the interlocking connection between the first part and the second part is against compressive, shear and tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
[0040] According to some embodiments, the first protrusions, the first recesses, the second protrusions and the second recesses have a "T" shape.
[0041] With such a configuration of the protrusions and the recesses, the interlocking connection between the first part and the second part is against compressive, shear and tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
[0042] According to some embodiments, the first protrusions, the first recesses, the second protrusions and the second recesses have a crenelated shape.
[0043] With such a configuration of the protrusions and the recesses, the interlocking connection between the first part and the second part is against compressive and shear forces occurring in the interlocking connection plane when the first part and the second part are flat.
[0044] According to some embodiments, the first protrusions and the second protrusions have different shapes and dimensions.
[0045] All the first protrusions may have the same shape and dimensions and all the second protrusions may have the same shape and dimensions, while the shape and dimensions of the first protrusions may differ from the shape and dimensions of the second protrusions. Thus, all first recesses have the same shape and dimensions and all the second recesses have the same shape and dimensions, the first recesses being complementary to the second protrusions and the second recesses being complementary to the first protrusions.
[0046] The first protrusions may have a shape of a mushroom, while the second protrusions have the complementary shape of the first recesses which are delimited by the first protrusions.
[0047] With such a configuration of the protrusions and the recesses, the interlocking connection between the first part and the second part is against compressive, shear and tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
[0048] The first protrusions may have different shapes and dimensions, at least one first protrusion having a different shape and dimensions relative to the other first protrusions and the second protrusions may have different shapes and dimensions, at least one second protrusion having a different shape and dimensions relative to the other second protrusions.
[0049] With such a configuration of the protrusions and the recesses, the interlocking connection between the first part and the second part is against compressive and shear forces occurring in the interlocking connection plane when the first part and the second part are flat.
[0050] According to embodiments of the present disclosure, a method for making a piece by assembling a first part made of fibre reinforced thermoplastic and a second part made of fibre reinforced thermoplastic is provided. The method includes:
- cutting the first part in a first sheet of fibre reinforced thermoplastic, the first part comprising a first connecting edge made by alternating first protrusions and first recesses and cutting the second part in the first sheet or in a second sheet of fibre reinforced thermoplastic, the second part comprising a second connecting edge made by alternating second protrusions and second recesses, the first protrusions being complementary to the second recesses and the second protrusions being complementary to the first recesses;
- assembling the first part to the second part by interlocking the first connecting edge and the second connecting edge by receiving the first protrusions in the second recesses and the second protrusions in the first recesses, so as to form an interlocking connection between the first part and the second part against at least compressive and shear forces occurring in the interlocking connection plane when the first part and the second part are flat and an assembly of the first and the second parts;
- heating the assembly so as to obtain a softened assembly;
- forming the softened assembly in a shaping mould so as to obtain a formed assembly;
- overmoulding at least the interlocking connection of the formed assembly with a polymer so as to obtain the piece.
[0051] It is understood that the overmoulding may include a cooling step.
[0052] The heating step may be carried out in an infrared oven.
[0053] The heating temperature is between the glass transition temperature and the melting temperature of the thermoplastic.
[0054] According to some embodiments, the interlocking connection between the first part and the second part is against tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
[0055] According to some embodiments, the method includes a step of reinforcing the interlocking connection.
[0056] Reinforcement of the interlocking connection may help stabilizing the interlocking connection during handling of assembly and may prevent misalignment of the two parts in the shaping mould, as the parts are softened and more deformable than at room temperature.
[0057] According to some embodiments, in the step of reinforcing the interlocking connection is carried out between the assembling step and the heating step. [0058] According to some embodiments, the step of reinforcing the interlocking connection comprises stapling the interlocking connection with hot staples, each staple having a first leg into the first part and a second leg into the second part.
[0059] The use of hot staples allows carrying out the reinforcing step without warming up the first and the second part. Indeed, the hot staples soften the thermoplastic during penetration of the legs of the staples into the thermoplastic. The staples may be made of metallic alloys, such as steel. The staples may be made of polymer, such as polyamide.
[0060] According to some embodiments, the step of reinforcing the interlocking connection comprises hot pressing a sheet of fibres on the interlocking connection.
[0061] The sheet of fibres may improve guiding the injected thermoplastic during the overmoulding step.
[0062] According to some embodiments, the step of reinforcing the interlocking connection comprises hot pressing a sheet of fibres on each side of the interlocking connection.
[0063] According to some embodiments, the step of reinforcing the interlocking connection is carried out during the heating step.
[0064] According to some embodiments, the step of reinforcing the interlocking connection comprises stapling the interlocking connection with staples, each staple having a first leg into the first part and a second leg into the second part.
[0065] During the heating step, the thermoplastic of the first part and the second part is softened and the legs of the staples may penetrate into the thermoplastic. The staples may be made of metallic alloys, such as steel, or of polymer such as polyamide.
[0066] According to some embodiments, the step of reinforcing the interlocking connection comprises stitching the first part to the second part at the interlocking connection.
[0067] Stitching material may be a yarn, for example a polyester yarn, a polyamide yarn, etc.
[0068] It is intended that combinations of the above-described elements and those within the specification may be made, except where otherwise contradictory. [0069] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the disclosure, as claimed.
[0070] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the description, serve to explain the principles thereof.
BRIEF DESCRIPTION OF THE DRAWINGS [0071] Fig. 1 shows a representation of a sheet of fibre reinforced thermoplastic showing known cutting;
Fig. 2 shows a representation of an exemplary piece according to embodiments of the present disclosure;
Fig. 3 shows a representation of an exemplary sheet of fibre reinforced thermoplastic showing cutting according to embodiments of the present disclosure;
Fig. 4 shows a representation of an exemplary first part and second part according to embodiments of the present disclosure;
Fig. 5 shows a representation of an exemplary assembly according to embodiments of the present disclosure;
Fig. 6 shows a representation of an exemplary formed assembly according to embodiments of the present disclosure;
Fig. 7 shows a schematic representation of an enlargement Fig. 4;
Fig. 8 shows the parts of Fig. 7 during assembly;
Fig. 9 shows the parts of Fig. 7 after assembly;
Fig. 10 shows the parts of Fig. 7 after overmoulding;
Figs. 11-14 show enlargements of other exemplary assemblies according to embodiments of the present disclosure;
Fig. 15 shows the step of overmoulding according to embodiments of the present disclosure;
Figs. 16A-16C show the covering of the interlocking connection with two sheets of fibres according to embodiments of the present disclosure;
Fig. 17 shows a representation of an exemplary assembly with reinforced interlocking connection according to embodiments of the present disclosure; Figs. 18 and 19 show other exemplary assemblies with reinforced interlocking connection according to embodiments of the present disclosure; and
Fig. 20 shows a flow chart of the method according to embodiments of the present disclosure.
DETAILED DESCRIPTION
[0072] Reference will now be made in detail to exemplary embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts.
[0073] Fig. 2 shows a representation of an exemplary piece 10 according to embodiments of the present disclosure. The piece 10 includes a first part 12 and a second part 14, each made of fibre reinforced thermoplastic, the first part 12 and the second part 14 being overmoulded with a polymer 16.
[0074] Fig. 20 shows a flow chart of a method 100 for making the piece 10 according to embodiments of the present disclosure.
[0075] As shown at Fig. 3, the method includes a step 102 of cutting the first part 12 and the second part 14 in a sheet 18 of fibre reinforced thermoplastic.
[0076] As may be seen by comparing Figs. 1 and 3, it is possible to reduce the part of the sheet 18 of fibre reinforced thermoplastic that is discarded as waste material, as it is possible to cut one more piece from the sheet 18 in Fig. 3 than it was possible to cut in Fig. 1.
[0077] For example, the first part 12 and the second part 14 may be cut from the same sheet 18 of fibre reinforced thermoplastic. The first part 12 and the second part 14 may be cut from two different sheets 18.
[0078] The sheet of fibre reinforced thermoplastic may be continuous glass fibre reinforced polypropylene having a thickness 20A of 2 mm (see Fig. 15). For example, glass fibre reinforced polypropylene such as Lanxess Tepex® dynalite 104-RG600(2)-RGUDm317(4)/48% black Typ S) with a (0/90/- 45/+45)s layup may be used.
[0079] As shown at Fig. 3, the first part 12 includes a first connecting edge 12A and the second part 14 includes a second connecting edge 14A. [0080] As shown at Figs. 4 and 5, the first part 12 and the second part 14 are assembled together along the first and second connecting edges 12A, 14A. The assembled the first and second connecting edges 12A, 14A forms an interlocking connection 22 between the first part 12 and the second part 14. Once the assembling step 104 is carried out, an assembly 20 of the first part 12 and the second part 14 is obtained.
[0081] The assembly 20 is flat and has the thickness of the sheet 18 in which the first part 12 and the second part 14 have been cut.
[0082] As shown at Fig. 5, the interlocking connection 22 acts in keeping the first part 12 and the second part 14 together against at least compressive C and shear S forces that may occur in the interlocking connection plane when the first part 12 and the second part 14 are flat, i.e., as represented at Fig. 5.
[0083] At step 106, the assembly 20 is heated so as to obtain a softened assembly, i.e., an assembly at which temperature the thermoplastic is softened and can be deformed without breaking. The heating step 106 may be carried out in an infrared oven between the glass transition temperature and the melting temperature of the thermoplastic.
[0084] At step 108, the softened assembly is then placed in a shaping mould 120 (see Fig. 15) to give the softened assembly the desired form, thus obtaining a formed assembly 24, as represented at Fig. 6. The formed assembly 24 is formed by the softened assembly being pushed against a lower part 120B of the shaping mold 120. The mold 120 then closes and an upper part 120A of the shaping mold 120 may touch the softened assembly and form it.
[0085] Once the formed assembly 24 is obtained, the overmoulding of the formed assembly 24 may take place during overmoulding step 110. During step 110, as shown at Fig. 6, the formed assembly 24 rest against the lower part 120B of the shaping mould 120 and polymer 16 is injected into cavities 120C of the shaping mould 120 present between the formed assembly 24 and the upper part 120A of the shaping mould 120, so that the polymer 16 finally pushes the formed assembly 24 against the lower part 120B which gives the final shape.
[0086] Once the cavity 120C is filled with the polymer 16, the injection of polymer stops and the polymer is treated so as to become hard. Thus, at the end of step 110, the piece 10 is obtained. [0087] When the polymer 16 is a thermoplastic polymer, the polymer hardened by lowering the temperature of the polymer. When the polymer 16 is a thermosetting polymer, the polymer is cured.
[0088] As shown at Figs. 7-10, the method 100 may be applied to first and second parts 12, 14 having first and second connecting edges 12A, 14A, made by alternating protrusions and recesses having the same shape and dimensions.
[0089] As shown at Fig. 7, when cutting the first part 12, one cuts the first connecting edge 12A, which is made by alternating first protrusions 12B and first recesses 12C. In the non-limiting example of Fig. 7, the first protrusions 12B and the first recesses 12C have a dovetail shape. Likewise, when cutting the second part 14, one cuts the second connecting edge 14A, which is made by alternating second protrusions 14B and second recesses 14C. In the nonlimiting example of Fig. 7, the second protrusions 14B and the second recesses 14C have a dovetail shape. The first protrusions 12B have shape complementary to the shape of the second recesses 14C and the second protrusions 14B have shape complementary to the shape of the first recesses 12C.
[0090] As shown at Fig. 9, the assembly of the first part 12 to the second part 14 is made by interlocking the first connecting edge 12A and the second connecting edge 14A by receiving the first protrusions 12B in the second recesses 14C and the second protrusions 14B in the first recesses 14B, so as to form the interlocking connection 22 between the first part 12 and the second part 14. Thus, the first protrusions 12B, first recesses 12C, second protrusions 14B and second recesses 14C are forming the interlocking connection 22 between the first part 12 and the second part 14.
[0091] With such a configuration of the first and second protrusions 12B, 14B and the first and second recesses 12C, 14C, the interlocking connection 22 between the first part 12 and the second part 12 is against compressive C, shear S and tensile T forces occurring in the interlocking connection plane when the first part 12 and the second part 14 are flat.
[0092] As shown at Fig. 10, after the overmoulding step 110, the polymer 16 is at least overmoulded over the interlocking connection 22, i.e., the polymer is overmoulded over the interlocking connection 22 and other parts of the formed assembly 24 may also be covered with the overmoulded polymer 16. [0093] Figs. 11-14 are similar to Fig. 9. Fig. 11-14 are representations of other exemplary assemblies according to embodiments of the present disclosure.
[0094] The assembly 20 of Fig. 11 differs from the assembly 20 of Fig. 9 in that the first protrusions 12B, the first recesses 12C, the second protrusions 12C and the second recesses 12C have a "T" shape. First and second parts 12, 14 having first and second connecting edges 12A, 14A, are made by alternating protrusions and recesses having the same shape and dimensions.
[0095] With such a configuration of the first and second protrusions 12B, 14B and the first and second recesses 12C, 14C, the interlocking connection 22 between the first part 12 and the second part 12 is against compressive C, shear S and tensile T forces occurring in the interlocking connection plane when the first part 12 and the second part 14 are flat.
[0096] The assembly 20 of Fig. 12 differs from the assembly 20 of Fig. 9 in that the first protrusions 12B have a mushroom shape, i.e., each first protrusion 12B has a stem 12BA and a head 12BB. The second protrusions 14B have a shape complementary to the shape of the first recesses 12C, which are delimited by two consecutive protrusions 12B. Thus, all the first protrusions 12B have the same shape and dimensions, all the second protrusions 14B have the same shape and dimensions and the first protrusions 12B and the second protrusions 14B have different shape and dimensions.
[0097] With such a configuration of the first and second protrusions 12B, 14B and the first and second recesses 12C, 14C, the interlocking connection 22 between the first part 12 and the second part 12 is against compressive C, shear S and tensile T forces occurring in the interlocking connection plane when the first part 12 and the second part 14 are flat.
[0098] The assembly 20 of Fig. 13 differs from the assembly 20 of Fig. 9 in that the first connecting edge 12A and the second connecting edge 12B have a crenelated shape, i.e., the first protrusions 12B, the first recesses 12C, the second protrusions 12C and the second recesses 12C have a crenelated shape. The first protrusions 12B, the first recesses 12C, the second protrusions 12C and the second recesses 12C have the same shape and dimensions.
[0099] With such a configuration of the first and second protrusions 12B, 14B and the first and second recesses 12C, 14C, the interlocking connection 22 between the first part 12 and the second part 12 is against compressive C and shear S forces occurring in the interlocking connection plane when the first part 12 and the second part 14 are flat.
[0100] The assembly 20 of Fig. 14 differs from the assembly 20 of Fig. 9 in that the first protrusions 12BA have different shape and dimensions from first protrusions 12BB. The second protrusions 14B have a shape complementary to the shape of the first recesses 12C, which are delimited by two consecutive protrusions 12B. Thus, the first protrusions 12B have different shape and dimensions, the second protrusions 14B have different shape and dimensions and the first protrusions 12B and the second protrusions 14B have different shape and dimensions.
[0101] With such a configuration of the first and second protrusions 12B, 14B and the first and second recesses 12C, 14C, the interlocking connection 22 between the first part 12 and the second part 12 is against compressive C and shear S forces occurring in the interlocking connection plane when the first part 12 and the second part 14 are flat.
[0102] Figs. 17-19 are representation of exemplary reinforced interlocking connections 22.
[0103] As shown at Fig. 17, the interlocking connection 22 is covered by a sheet 26 of fibres which is impregnated by the thermoplastic material of both the first part 12 and the second part 14. For the sheet 26, a continuous glass fiber reinforced polypropylene UD tape material (Sabic UDmax GPP 45-70) may be used.
[0104] In the non-limiting example of Fig. 17, the external surface of the sheet 26 of fibres is flush with the surface of the first part 12 and the second part 14. The sheet 26 of fibres does not add an extra thickness to the first and second parts 12, 14. Glass, carbon, aramid or natural fiber may be used. Non- woven (for example glass fiber non-woven with an areal weight of 34 g/m2 and a thickness (non-woven only of 0,29 mm) or glass fiber UD tape with a thickness of 0,25 mm, fiber content of 45 vol-% and polypropylene matrix may be used.
[0105] As shown at Fig. 17, the sheet 26 of fibres is applied on one side of the interlocking connection 22.
[0106] As another non-limiting example, the sheet 26 of fibres may cover both sides of the interlocking connection 22. [0107] As shown at Figs. 16A-16C and 20, the step 112 of reinforcing the interlocking connection 22 may take place between the assembling step 104 and the heating step 106.
[0108] The sheet(s) 26 of fibres may be hot pressed on the assembly 20 before heating.
[0109] As shown at Fig. 16A, the thickness 26A of the sheet 26 of fibres is small compared to the thickness 20A of the assembly 20. As non-limiting example, the thickness 26A may be equal to 0,2 mm.
[0110] The assembly 20 and the sheet(s) 26 of fibres are placed in the cavity of a hot press 140 between an upper plate 140A and a lower plate 140B, the sheet(s) 26 of fibres being disposed on the upper plate 140A and/or the lower plate 140B so as cover the interlocking connection 22 when the reinforcing step 112 is finished. The sheet(s) 26 of fibres may be attached to the upper plate 140A and/or the lower plate 140B by vacuum holders. The upper and lower plates 140A, 140B are heated and bring close to one another so as to press the sheet(s) 26 of fibres into the assembly 20. Under the action of the heat, the thermoplastic of the assembly 20 partially melts and penetrates into the sheet(s) 26 of fibres, the thermoplastic being present between the fibres of the sheet(s) 26 of fibres. The sheet(s) is/are thus impregnated, at least partially, with the thermoplastic material of the assembly 20.
[0111] The upper plate 140A and the lower plate 140B may be further bring closer to one another and the sheet(s) 26 of fibres are further pushed towards and in the assembly 20 so as to form a surface that is flush with the surface of the assembly 20.
[0112] As shown at Fig. 18, the interlocking connection 22 may be reinforced with staples 28 disposed along the interlocking connection 22, each staple 28 including a first leg 28A and a second leg 28B linked together by a crown 28C. Each staple 28 has the first leg 28A passing through the first part 12 and folded over the first part 12 and the second leg 28B passing through the second part 14 and folded over the second part 14, the crown 28C thus crossing the interlocking connection 22.
[0113] As show at Fig. 20, the reinforcing step 112 may be carried out either between the assembling step 104 and the heating step 106 or during the heating step 106. [0114] When carried out between the assembling step 104 and the heating step 106, it is preferable that the stapes 28 be heated. The use of hot staples 28 allows carrying out the reinforcing step 112 without warming up the first and the second parts 12, 14. Indeed, the hot staples 28 soften the thermoplastic during penetration of the legs 28A, 28B of the staples 28 into the thermoplastic. The staples may be made of metallic alloys, such as steel, or of polymer such as polyamide.
[0115] When carried out during the heating step 106, the staples 28 need not be heated. During the heating step 106, the thermoplastic of the first part 12 and the second part 14 is softened and the legs 28A, 28B of the staples 28 may penetrate into the thermoplastic. The staples may be made of metallic alloys or of polymer.
[0116] As shown at Fig. 19, the interlocking connection 22 may be reinforced by stitching the first part 12 to the second part 14 at the interlocking connection 22.
[0117] During the heating step 106, the thermoplastic of the first part 12 and the second part 14 is softened and the first part 12 may be stitched to the second part 14 at the interlocking connection 22.
[0118] Throughout the description, including the claims, the term "comprising a" should be understood as being synonymous with "comprising at least one" unless otherwise stated. In addition, any range set forth in the description, including the claims should be understood as including its end value(s) unless otherwise stated. Specific values for described elements should be understood to be within accepted manufacturing or industry tolerances known to one of skill in the art, and any use of the terms "substantially" and/or "approximately" and/or "generally" should be understood to mean falling within such accepted tolerances.
[0119] Although the present disclosure herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure.
[0120] It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims.

Claims

1. A piece (10) comprising a first part (12) made of fibre reinforced thermoplastic and comprising a first connecting edge (12A) made by alternating first protrusions (12B) and first recesses (12C), and a second part (14) made of fibre reinforced thermoplastic and comprising a second connecting edge (14A) made by alternating second protrusions (14B) and second recesses (14C), the first protrusions (12B) being complementary to the second recesses (14C) and being received in the second recesses (14C) and the second protrusions (14B) being complementary to the first recesses (12C) and being received in the first recesses (12C), the first protrusions (12B), first recesses (12C), second protrusions (14B) and second recesses (14C) forming an interlocking connection (22) between the first part (12) and the second part (14) against at least compressive and shear forces occurring in the interlocking connection plane when the first part (12) and the second part (14) are flat, the interlocking connection being overmoulded with a polymer (16).
2. The piece (10) according to claim 1, wherein the interlocking connection (22) between the first part (12) and the second part is against tensile forces occurring in the interlocking connection plane when the first part (12) and the second part (14) are flat.
3. The piece (10) according to claim 1 or 2, wherein staples are disposed along the interlocking connection (22), each staple having a first leg (28A) into the first part (12) and a second leg (28B) into the second part (14).
4. The piece (10) according to any of claims 1-3, wherein a sheet (26) of fibres is at least partially impregnated by the thermoplastic material of both the first part (12) and the second part (14), the sheet (26) of fibres covering the interlocking connection (22).
5. The piece (10) according to claim 4, wherein the sheet (26) of fibres is a first sheet (26) of fibres and a second sheet of fibres is at least partially impregnated by the thermoplastic material of both the first part (12) and the second part (14), the second sheet covering the interlocking connection (22), so that both sides of the interlocking connection (22) are covered.
6. The piece (10) according to claim 4 or 5, wherein the sheet (26) of fibres is a sheet of fibre reinforced thermoplastic.
7. The piece (10) according to claim 1 or 2, wherein the first part (12) is stitched to the second part (14) at the interlocking connection (22).
8. The piece (10) according to any of claims 1-7, wherein the first protrusions (12B) and the second protrusions (14B) have the same shape and dimensions.
9. The piece (10) according to claim 8, wherein the first protrusions (12B), the first recesses (12C), the second protrusions (14B) and the second recesses (14C) have a dovetail shape.
10. The piece (10) according to any of claims 1-7, wherein the first protrusions (12B) and the second protrusions (14B) have different shapes and dimensions.
11. A method (100) for making a piece (10) by assembling a first part (12) made of fibre reinforced thermoplastic and a second part (14) made of fibre reinforced thermoplastic, comprising:
- cutting (102) the first part (12) in a first sheet (18) of fibre reinforced thermoplastic, the first part (12) comprising a first connecting edge (12A) made by alternating first protrusions (12B) and first recesses (12C) and cutting the second part (14) in the first sheet (18) or in a second sheet of fibre reinforced thermoplastic, the second part (14) comprising a second connecting edge (14A) made by alternating second protrusions (14B) and second recesses (14C), the first protrusions (12B) being complementary to the second recesses (14C) and the second protrusions (14B) being complementary to the first recesses (12C);
- assembling (104) the first part (12) to the second part (14) by interlocking the first connecting edge (12A) and the second connecting edge (14A) by receiving the first protrusions (12B) in the second recesses (14C) and the second protrusions (14B) in the first recesses (14B), so as to form an interlocking connection (22) between the first part (12) and the second part (14) against at least compressive and shear forces occurring in the interlocking connection plane when the first part (12) and the second part (14) are fiat and an assembly (20) of the first and the second parts (12, 14);
- heating (106) the assembly (20) so as to obtain a softened assembly; - forming (108) the softened assembly in a shaping mould (120) so as to obtain a formed assembly (24);
- overmoulding (110) at least the interlocking connection (22) of the formed assembly (24) with a polymer so as to obtain the piece (10).
12. The method (100) according to claim 11, wherein the interlocking connection between the first part and the second part is against tensile forces occurring in the interlocking connection plane when the first part and the second part are flat.
13. The method (100) according to claim 11 or 12, comprising a step of reinforcing (112) the interlocking connection (22).
14. The method (100) according to claim 13, wherein in the step of reinforcing (112) the interlocking connection (22) is carried out between the assembling step (104) and the heating step (106).
15. The method (100) according to claim 14, wherein the step of reinforcing (112) the interlocking connection (22) comprises stapling the interlocking connection (22) with hot staples, each staple having a first leg into the first part and a second leg into the second part.
16. The method (100) according to claim 14 or 15, wherein the step of reinforcing (112) the interlocking connection (22) comprises hot pressing a sheet (26) of fibres on the interlocking connection (22).
17. The method (100) according to claim 14 or 15, wherein the step of reinforcing (112) the interlocking connection (22) comprises hot pressing a sheet (26) of fibres on each side of the interlocking connection (22).
18. The method (100) according to claim 13, wherein the step of reinforcing (112) the interlocking connection (22) is carried out during the heating step (106).
19. The method (100) according to claim 18, wherein the step of reinforcing (112) the interlocking connection (22) comprises stapling the interlocking connection (22) with staples (28), each staple (28) having a first leg (28A) into the first part (12) and a second leg (28B) into the second part (14).
20. The method (100) according to claim 18 or 19, wherein the step of reinforcing (112) the interlocking connection (22) comprises stitching the first part (12) to the second part (14) at the interlocking connection (22).
PCT/EP2019/052783 2019-02-05 2019-02-05 Piece made of two fibre reinforced thermoplastic parts and method for making the same WO2020160758A1 (en)

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DE112019006819.9T DE112019006819T5 (en) 2019-02-05 2019-02-05 Piece made from two fiber reinforced thermoplastic sections and method of making the same

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EP4129810A1 (en) * 2021-08-02 2023-02-08 A-Pro Tech Co., Ltd. Bicycle frame component and method for thermoforming the same

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JP2006123277A (en) * 2004-10-27 2006-05-18 Mitsubishi Heavy Ind Ltd Frp structure, frp windmill blade, and method for joining frp hollow member
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DE29918374U1 (en) * 1999-10-19 2000-11-23 Heimbach Gmbh Thomas Josef Textile tape with sewing thread
JP2006123277A (en) * 2004-10-27 2006-05-18 Mitsubishi Heavy Ind Ltd Frp structure, frp windmill blade, and method for joining frp hollow member
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EP4129810A1 (en) * 2021-08-02 2023-02-08 A-Pro Tech Co., Ltd. Bicycle frame component and method for thermoforming the same

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