Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B9/00—Making granules
  • B29B9/12—Making granules characterised by structure or composition
  • B29B9/14—Making granules characterised by structure or composition fibre-reinforced
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B9/00—Making granules
  • B29B9/02—Making granules by dividing preformed material
  • B29B9/04—Making granules by dividing preformed material in the form of plates or sheets
• • 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
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
• • 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
  • B29C70/06—Fibrous reinforcements only
  • B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
  • B29C70/16—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length
  • B29C70/20—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of substantial or continuous length oriented in a single direction, e.g. roofing or other parallel 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
  • 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
  • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
• • 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
  • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
  • B29C70/545—Perforating, cutting or machining during or after moulding
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C2793/00—Shaping techniques involving a cutting or machining operation
  • B29C2793/0081—Shaping techniques involving a cutting or machining operation before shaping
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C2793/00—Shaping techniques involving a cutting or machining operation
  • B29C2793/009—Shaping techniques involving a cutting or machining operation after shaping
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2071/00—Use of polyethers, e.g. PEEK, i.e. polyether-etherketone or PEK, i.e. polyetherketone or derivatives thereof, as moulding material
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
  • B29K2101/10—Thermosetting resins
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2101/00—Use of unspecified macromolecular compounds as moulding material
  • B29K2101/12—Thermoplastic materials
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
  • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
  • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
  • B29K2105/0872—Prepregs
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
  • B29K2307/00—Use of elements other than metals as reinforcement
  • B29K2307/04—Carbon

Definitions

• U.S. Patent Publication No. 2013/0189478 Al discloses use of narrow flakes of a ratio of at least 6: 1 height to width to form composites of a consistent uniform strength.
• U.S. Patent No. 9,724,854 describes forming composites from chips formed from unidirectional tape using thermosetting resins. The chips are rectangular structure, but may be in other shapes depending on how the unidirectional tape is chopped.
• the at least one exterior edge feature in the embodiments of the method noted above may be configured to have a shape selected from a triangle shape (such as in the zig zag pattern noted above), but may also be, a parabola shape, a parallelogram shape, a bell shape, a bullet shape, an arrowhead shape and/or a trapezoid shape.
• each exterior edge feature may be the same or different.
• the edge features may form a pattern.
• the at least one exterior edge portion may also in another preferred embodiment be shaped as a parallelogram such as a rectangle, e.g., to form a rectangular toothed configuration in a pattern form.
• the polymeric matrix material may be a thermoplastic and is one or more of a polysulfone, a polysulfide, a polyimide, a polyaramid, a polyamideimide, a polyamide, a polyarylene polymer, a fluoropolymer, and combinations and copolymers thereof.
• the polymeric matrix material may further be a polyarylene polymer that is one or more of polyether ketones, polyetherether ketones, polyetherketone ketones, and combinations and copolymers thereof.
• the long reinforcing fibers in the at least one modified polymeric composite flake used in the method may be one or more of inorganic fibers, ceramic fibers, glass fibers, graphite fibers, carbon fibers, and organic fibers which may be thermoplastic fibers or thermosetting fibers, and combinations thereof.
• the at least two of the exterior edge features in the plurality of exterior edge features may also be contiguous and form a vertex of an angle at a point of contact between the at least two angled sides.
• the at least two of the exterior edge features in the plurality of exterior edge features may also be contiguous so that the at least one portion of the exterior edge of each of the plurality of flakes having the exterior edge features may comprise a zig zag pattern.
• Each of the modified polymeric composite flakes may comprise at least three exterior edge portions, at least two of which have the zig zag pattern.
• G works as a camshaft, synchronized with the movement of motor J.
• G includes a cutting blade (GB) that is also synchronized with the movement of motor J.
• the apparatus may further include a built-in or independently operable controller for controllably setting and operating the feeder and/or the cutting device.
• Control such as numerical control, of the above-noted cutting device G, may be used to control the operation of the motor J that advances a composite tape as well as to control the motor that drives the camshaft in cutting device G and hence also controls the position of the guillotine type blade(s) (GB).
• the apparatus A is shown for use in forming the modified polymeric composite flakes of the Examples herein, it may be formed in a larger industrial scale with a variety of feeders and cutting devices with interchangeable or fixed cutting templates.
• standard polymeric composite flakes as referenced herein when used with modified polymeric composite flakes according to the method, that is, commercial composite flakes that are not modified, may be represented generally with reference to an example of a polymeric composite flake 10, having a length I extending in along a longitudinal axis x-x’ through the flake and a width w measured orthogonally to the length I and extending along a transverse axis y-y’, or if circular, as shown in an alternative commercial type unmodified flake 10’ in Fig. 2, such a flake may have a diameter d. If the flake is square, the length I and the width w would necessarily be the same. It is noted that corresponding reference numbers herein are used for analogous features in the flakes of Figs. 1, 1 A and 2.
• thermoplastics such as polysulfones, polyimides, polyamideimides, polyetherimides, polyamides, polyphenylene oxides and sulfides, and the polyarylene materials, such as PEEK, PEK, PEKEKK, and PEKK.
• the exterior edge features may be made with any suitable cutting device, including a pair of scissors, shears, a knife, an automatic chopping device, a die-cutting machine, a saw, a cutting blade, a drill, a grinder, an abrasive waterjet, and a laser beam cutting device as well as the device described herein and shown in Fig. 24. It is also possible to use composite materials to form modified polymeric composite flake(s) herein having the long reinforcing fibers and matrix materials described herein. If desired, roughing the surfaces once the edge features are formed may also be provided for modifying edge properties.
• the angled sides are angled toward one another to form an angle a’ with respect to each other having a projected vertex V2 outside the ends of the angled sides as shown in Fig. 4.
• the sides 128a’, 128b’ are not contiguous.
• the patterned features are connected by a linear edge portion 130’ and are configured in a pattern that is like a “dovetail” design.
• the pattern on one edge portion is a reverse pattern on the opposing edge portion so that an outwardly extending trapezoid on a first edge portion is longitudinally aligned (preferably in a fiber direction) with an inwardly extending trapezoidal gap on the opposing edge portion. This arrangement provides the optional benefit of maintaining the fiber length as consistent from one end of the pattern of exterior edge features to the other end thereof.
• Figs. 18 and 20 are examples of flakes having only one exterior edge feature on an exterior edge portion. Such feature is positioned on each of two opposing edge portions. In Fig. 18, the edge feature is triangular, whereas in Fig. 20, the edge feature is a single, fully curved feature. In Fig.
• the molding process included forming the flakes by cutting with a device capable of chopping a unidirectional tape into repeatable flake geometries.
• the required quantity of flakes was weighed and filled by hand (but could have been filled by a robotic system) so as to evenly spread the flakes into a square mold cavity having dimensions of 12 in. X 12 in.
• the mold was heated in a hot press to about 400°C, although processing temperatures of between about 360°C and about 430°C may be used.
• the material was subjected to applied pressure of about 100 bar. Process pressures of about 60 bar to about 150 bar on the material may be used.
• the material was then cooled down in a cold press under the same applied pressure.
• the plates made were about 0.1 in. in thickness, and each was machined into seven (7) dog bone-shaped samples of 1 in. width.
• the invention herein also provides a method of increasing one or more of an average tensile strength and/or impact resistance, particularly high-velocity impact resistance for articles formed using the modified polymeric composite flakes having the exterior edge features in comparison to articles formed from standard unmodified composite flake formed so as to have a polymeric matrix material and reinforcing long fiber(s) therein extending through the flake.
• the improvement is derived from providing one or more of the exterior edge features as described hereinabove to portions of the exterior edges of modified polymeric composite flakes provided herein using techniques as described above. Fatigue limit for such articles may also be increased using the modified flakes and methods herein.

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• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Chemical & Material Sciences (AREA)
• Composite Materials (AREA)
• Textile Engineering (AREA)
• Reinforced Plastic Materials (AREA)
• Compositions Of Macromolecular Compounds (AREA)

Priority Applications (5)

Applications Claiming Priority (2)

Publications (2)

Family

ID=87766817

Family Applications (1)

Country Status (8)

Family Cites Families (8)

• 2023
  • 2023-02-28 CA CA3245041A patent/CA3245041A1/en active Pending
  • 2023-02-28 JP JP2024550768A patent/JP2025507753A/ja active Pending
  • 2023-02-28 US US18/175,989 patent/US20240058992A1/en active Pending
  • 2023-02-28 WO PCT/US2023/063406 patent/WO2023164725A2/en not_active Ceased
  • 2023-02-28 KR KR1020247032517A patent/KR20240160601A/ko active Pending
  • 2023-02-28 CN CN202380036668.9A patent/CN119698352A/zh active Pending
  • 2023-02-28 EP EP23761036.5A patent/EP4486554A4/en active Pending
  • 2023-03-01 TW TW112107310A patent/TW202339935A/zh unknown

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