JP4812760B2 - 自動車のヘッドライナー用の再生可能な複合プラスチック - Google Patents
自動車のヘッドライナー用の再生可能な複合プラスチック Download PDFInfo
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- JP4812760B2 JP4812760B2 JP2007522022A JP2007522022A JP4812760B2 JP 4812760 B2 JP4812760 B2 JP 4812760B2 JP 2007522022 A JP2007522022 A JP 2007522022A JP 2007522022 A JP2007522022 A JP 2007522022A JP 4812760 B2 JP4812760 B2 JP 4812760B2
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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
- 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
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—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
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/08—Reinforcements
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/70—Scrap or recycled material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24058—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in respective layers or components in angular relation
- Y10T428/24124—Fibers
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24132—Structurally defined web or sheet [e.g., overall dimension, etc.] including grain, strips, or filamentary elements in different layers or components parallel
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
- Moulding By Coating Moulds (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Description
第1のポリマーであって長尺な又は連続的で平行な繊維強化熱可塑性プラスチック製の第1の強化層を提供する工程と、
第1のポリマーに適合可能である第2のポリマーであって熱可塑性プラスチックのコア層を提供する工程と、
該第1のポリマーであって長尺な又は連続的で平行な繊維強化熱可塑性プラスチック製の第2の強化層を提供する工程と、
コア層によって強化層を互いに離間するように該第1の強化層、該コア層、該第2の強化層を積層して積層体を形成する工程と、
該積層体をパネルの金型に導入すると共に金型を少なくとも所定のポリマーの融点まで加熱し、それにより層を圧密化してパネルを形成する工程とを備えたパネル製造方法が提供される。
各層は、販売されている製品から構成されてもよいが、本方法によって生成されるハイブリッド構造体は、いかなる出発材料によっても達成することができない、本明細書で概要を述べたような有益な特性を有する。
Claims (22)
- 表面の曲率が不連続な形状のパネルを製造する方法であって、
互いに平行な長繊維及び又は連続繊維で強化された第1のポリマーである熱可塑性プラスチック製の第1の強化層を提供する工程と、
該第1のポリマーと相溶性である第2のポリマーである熱可塑性プラスチック製のコア層を提供する工程と、
互いに平行な長繊維又は連続繊維で強化された該第1のポリマーである熱可塑性プラスチック製の第2の強化層を提供する工程と、
2つの付加的な強化層を提供する工程と、
該コア層によって該強化層を離間するように該層を積層する工程と、
該積層をパネルの金型に導入すると共に該金型を少なくとも所定のポリマーの融点まで加熱し、該層を圧密化して該パネルを成形する工程とを備え、
該積層する工程において2つの付加的な強化層の一方は該コア層の一方の面側に配置され、他方は該コア層の他方の面側に配置され、
該積層する工程において、外層となる強化層の繊維は第一方向に延び、該内層となる強化層の繊維は該第一方向と直交する第2方向に延びるか又は擬似等方性配向で斜めに交差していることを特徴とするパネル製造方法。 - 該コア材料は(i)該第2のポリマーを約70容量%含むか、又は(ii)該パネルの50容量%を占めることを特徴とする請求項1に記載のパネル製造方法。
- 成形された該パネルを火炎処理、コロナ放電又はプラズマ銃により処理する工程を更に備えたことを特徴とする請求項1又は2に記載のパネル製造方法。
- 該第1のポリマー及び該第2のポリマーが互いに同一のポリマーであるか、又は実質的に同じポリマーであることを特徴とする請求項1〜3のいずれか1項に記載のパネル製造方法。
- 該成形工程が真空圧密金型又はスタンププレス金型を用いて行われることを特徴とする請求項1〜4のいずれか1項に記載のパネル製造方法。
- 該金型の少なくとも一部が加熱されることを特徴とする請求項1〜5のいずれか1項に記載のパネル製造方法。
- 塗装されるべき該パネルの側面の成形に対応する少なくとも1つの金型ツーリング面が加熱されることを特徴とする請求項6に記載のパネル製造方法。
- 該積層を加熱する工程において、該金型の少なくとも一部を冷却する工程を備えることを特徴とする請求項1〜7のいずれか1項に記載のパネル製造方法。
- 該ツーリング表面のみを冷却することを特徴とする請求項7に従属する請求項8に記載のパネル製造方法。
- 該パネルの厚さの約50%を占めるように該コア層を提供することを特徴とする請求項1〜9のいずれか1項に記載のパネル製造方法。
- 3つ以上の強化層を提供することを特徴とする請求項1〜10のいずれか1項に記載のパネル製造方法。
- 該コア層の片面側に配置された複数の該強化層と、該コア層の反対面側に配置された複数の該強化層とは実質的に鏡像関係にあることを特徴とする請求項1〜11のいずれか1項に記載のパネル製造方法。
- 該第1強化層と該第2強化層とを提供する工程において、該繊維を層中に組み込む前に該繊維を相互に編成することを特徴とする請求項1に記載のパネル製造方法。
- 該コア層を提供する工程において、該コア層は強化用繊維を含むことを特徴とする請求項1〜13のいずれか1項に記載のパネル製造方法。
- 該コアが、再生材料、産業用粉砕再生材料、又は再利用目的の材料から構成されることを特徴とする請求項1〜14のいずれか1項に記載のパネル製造方法。
- 該パネルを自動車の製造に使用することを特徴とする請求項1〜15のいずれか1項に記載のパネル製造方法。
- 互いに平行な長繊維及び又は連続繊維で強化された第1のポリマーである熱可塑性プラスチック製の第1の強化層と、
該第1のポリマーと相溶性である第2のポリマーである熱可塑性プラスチック製のコア層と、
互いに平行な長繊維又は連続繊維で強化された該第1のポリマーである熱可塑性プラスチック製の第2の強化層と、
2つの付加的な強化層と、を有し、
該第1の強化層は該コア層の一方の面側に配置され、該第2の強化層は該コア層の他方の面側に配置され、
2つの付加的な強化層の一方は該コア層の一方の面側に配置され、他方は該コア層の他方の面側に配置されて積層体をなし、外層となる強化層の繊維は第一方向に延び、内層となる強化層の繊維は該第一方向と直交する第2方向に延びるか又は擬似等方性配向で斜めに交差しており、表面曲率が不連続であることを特徴とするパネル。 - 該コア材料は(i)該第2のポリマーを約70容量%含むか、又は(ii)該パネルの50容量%を占めることを特徴とする請求項17に記載のパネル。
- 該コア層の片面側に配置された複数の該強化層と、該コア層の反対面側に配置された複数の該強化層とは実質的に鏡像関係にあることを特徴とする請求項17又は18に記載のパネル。
- 該コア層は強化用繊維を含むことを特徴とする請求項17〜19のいずれか1項に記載のパネル。
- 該コアが、再生材料、産業用粉砕再生材料、又は再利用目的の材料から構成されることを特徴とする請求項17〜20のいずれか1項に記載のパネル。
- 自動車の一部に使用されることを特徴とする請求項17乃至21のいずれか1項に記載のパネル。
Applications Claiming Priority (5)
Application Number | Priority Date | Filing Date | Title |
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GB0416198.0 | 2004-07-20 | ||
GB0416197A GB0416197D0 (en) | 2004-07-20 | 2004-07-20 | Composite plastic and related manufacturing methods |
GB0416197.2 | 2004-07-20 | ||
GB0416198A GB0416198D0 (en) | 2004-07-20 | 2004-07-20 | Composite plastic and related manufacturing methods |
PCT/GB2005/002857 WO2006008529A1 (en) | 2004-07-20 | 2005-07-20 | Recyclable composite plastic for automotive headliner |
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JP2008506562A JP2008506562A (ja) | 2008-03-06 |
JP2008506562A5 JP2008506562A5 (ja) | 2011-08-25 |
JP4812760B2 true JP4812760B2 (ja) | 2011-11-09 |
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JP2007522022A Expired - Fee Related JP4812760B2 (ja) | 2004-07-20 | 2005-07-20 | 自動車のヘッドライナー用の再生可能な複合プラスチック |
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US (2) | US8021595B2 (ja) |
EP (1) | EP1773587B1 (ja) |
JP (1) | JP4812760B2 (ja) |
AT (1) | ATE552109T1 (ja) |
WO (1) | WO2006008529A1 (ja) |
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2005
- 2005-07-20 WO PCT/GB2005/002857 patent/WO2006008529A1/en active Application Filing
- 2005-07-20 JP JP2007522022A patent/JP4812760B2/ja not_active Expired - Fee Related
- 2005-07-20 AT AT05767925T patent/ATE552109T1/de active
- 2005-07-20 US US11/572,297 patent/US8021595B2/en not_active Expired - Fee Related
- 2005-07-20 EP EP05767925A patent/EP1773587B1/en not_active Not-in-force
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2011
- 2011-08-12 US US13/208,701 patent/US20120021166A1/en not_active Abandoned
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Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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KR20210035151A (ko) * | 2017-12-20 | 2021-03-31 | (주)엘지하우시스 | 연속섬유 강화 복합재를 표면층으로 포함하는 샌드위치 패널 |
KR102340130B1 (ko) * | 2017-12-20 | 2021-12-15 | (주)엘엑스하우시스 | 연속섬유 강화 복합재를 표면층으로 포함하는 샌드위치 패널 |
Also Published As
Publication number | Publication date |
---|---|
EP1773587B1 (en) | 2012-04-04 |
EP1773587A1 (en) | 2007-04-18 |
JP2008506562A (ja) | 2008-03-06 |
WO2006008529A1 (en) | 2006-01-26 |
ATE552109T1 (de) | 2012-04-15 |
US20080233342A1 (en) | 2008-09-25 |
US8021595B2 (en) | 2011-09-20 |
US20120021166A1 (en) | 2012-01-26 |
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