Lightweight composite thermoplastic sheets including reinforcing skins
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-005/26
B28B-005/00
출원번호
UP-0278748
(2006-04-05)
등록번호
US-7759267
(2010-08-09)
발명자
/ 주소
Conover, Amy M.
Davis, Scott
출원인 / 주소
Azdel, Inc.
대리인 / 주소
Armstrong Teasdale LLP
인용정보
피인용 횟수 :
11인용 특허 :
13
초록▼
A multi-layered fiber reinforced sheet for automotive vehicle interior structural components includes, in an exemplary embodiment, a permeable fiber reinforced thermoplastic core layer having a first surface and a second surface. The core layer includes a plurality of reinforcing fibers bonded toget
A multi-layered fiber reinforced sheet for automotive vehicle interior structural components includes, in an exemplary embodiment, a permeable fiber reinforced thermoplastic core layer having a first surface and a second surface. The core layer includes a plurality of reinforcing fibers bonded together with a thermoplastic resin, and has a density of about 0.1 gm/cc to about 1.8 gm/cc. The multi-layered fiber reinforced sheet also includes at least one first reinforcing skin applied to the first surface of the core layer, and at least one second reinforcing skin applied to the second surface of the core layer. Each first and second reinforcing skin includes a matrix of reinforcing fibers and a thermoplastic resin wherein the matrix of reinforcing fibers applied to the first surface are arranged in a bi-directional orientation and the matrix of reinforcing fibers applied to the second surface are arranged in a bi-directional orientation.
대표청구항▼
What is claimed is: 1. An automotive vehicle interior structural component comprising a molded multi-layered fiber reinforced material, said multi-layered fiber reinforced material comprising: a permeable fiber reinforced thermoplastic core layer comprising a plurality of reinforcing fibers bonded
What is claimed is: 1. An automotive vehicle interior structural component comprising a molded multi-layered fiber reinforced material, said multi-layered fiber reinforced material comprising: a permeable fiber reinforced thermoplastic core layer comprising a plurality of reinforcing fibers bonded together with a thermoplastic resin, said permeable core layer having a density of about 0.1 gm/cc to about 1.8 gm/cc and comprising a first surface and a second surface; two first reinforcing skins applied to said first surface, each said first reinforcing skin comprising a matrix of reinforcing fibers and a thermoplastic resin, said reinforcing fibers of each of said first reinforcing skins are unidirectional with said longitudinal axis of said reinforcing fibers orientated in one direction, said two first reinforcing skins are positioned so that said longitudinal axis of said reinforcing fibers of one of said first reinforcing skins is at an angle to said longitudinal axis of the other one of said first reinforcing skins creating a bi-directional orientation of said reinforcing fibers of said first reinforcing skins; and at least one second reinforcing skin applied to said second surface; each said second reinforcing skin comprising a matrix of reinforcing fibers and a thermoplastic resin wherein said matrix of reinforcing fibers applied to said second surface are arranged in a bi-directional orientation with at least a portion of said reinforcing fibers are unidirectional and are orientated so that a longitudinal axis of said portion of said reinforcing fibers are at an angle to a longitudinal axis of a remaining portion of unidirectional reinforcing fibers; said multi-layered fiber reinforced material molded at a temperature of about 160° F. and a molding cycle time of about 60 seconds of less. 2. A structural component in accordance with claim 1 wherein said multi-layered fiber reinforced material comprises two second reinforcing skins wherein said reinforcing fibers of each of said second reinforcing skins are unidirectional with said longitudinal axis of said reinforcing fibers orientated in one direction, said two second reinforcing skins are positioned so that said longitudinal axis of said reinforcing fibers of one of said second reinforcing skins is at an angle to said longitudinal axis of the other one of said second reinforcing skins creating a bi-directional orientation of said reinforcing fibers of said second reinforcing skins. 3. A structural component in accordance with claim 1 wherein each said first and second reinforcing skin comprises between about 50 weight percent and about 80 weight percent of reinforcing fibers. 4. A structural component in accordance with claim 1 wherein said core layer comprises about 20 weight percent to about 80 weight percent reinforcing fibers. 5. A structural component in accordance with claim 1 wherein said reinforcing fibers in said core and said first and second reinforcing skins comprise at least one of metal fibers, metalized inorganic fibers, metalized synthetic fibers, glass fibers, polyester fibers, polyamide fibers, graphite fibers, carbon fibers, ceramic fibers, mineral fibers, basalt fibers, inorganic fibers, aramid fibers, kenaf fibers, jute fibers, flax fibers, hemp fibers, cellulosic fibers, sisal fibers, and coir fibers. 6. A structural component in accordance with claim 1 wherein said thermoplastic resin in said core and saidfirst and second reinforcing skins comprise at least one of polyolefins, polyamides, polystyrene, acrylonitrylstyrene, butadiene, polyesters, polybutyleneterachlorate, polyvinyl chloride, polyphenylene ether, polyphenylene oxide, polyether imide, polycarbonates, polyestercarbonates, acrylonitrile-butylacrylate-styrene polymers, polybutyleneterephthalate, polyethyleneteraphthalate, and amorphous nylon. 7. A structural component in accordance with claim 1 further comprising a decorative layer applied to an outer surface of at least one of said first at least one reinforcing skin and said second at least one reinforcing skin. 8. A method of making an automotive vehicle interior structural component, said method comprising: forming a permeable fiber reinforced thermoplastic core layer comprising a plurality of reinforcing fibers bonded together with a thermoplastic resin, the permeable core layer having a density of about 0.1 gm/cc to about 1.8 gm/cc and having a first surface and a second surface; positioning two first reinforcing skin on the first surface, each first reinforcing skin comprising a matrix of reinforcing fibers and a thermoplastic resin, the reinforcing fibers of each of the first reinforcing skins are unidirectional with the longitudinal axis of the reinforcing fibers orientated in one direction, the two first reinforcing skins are positioned so that the longitudinal axis of the reinforcing fibers of one of the first reinforcing skins is at an angle to the longitudinal axis of the other one of the first reinforcing skins creating a bi-directional orientation of the reinforcing fibers of the first reinforcing skins; positioning at least one second reinforcing skin on the second surface; attaching the first reinforcing skins to the first surface; attaching the at least one second reinforcing layer to the second surface to form a multi-layered fiber reinforced sheet; and molding the multi-layered fiber reinforced sheet into a predetermined shape at a molding temperature of about 160° F. and a molding cycling time of about 60 seconds or less; each second reinforcing skin comprising a matrix of reinforcing fibers and a thermoplastic resin wherein the matrix of reinforcing fibers applied to the second surface are arranged in a bi-directional orientation with at least a portion of the reinforcing fibers are unidirectional and are orientated so that a longitudinal axis of the portion of the reinforcing fibers are at an angle to a longitudinal axis of a remaining portion of unidirectional reinforcing fibers. 9. A method in accordance with claim 8 wherein the multi-layered fiber reinforced sheet comprises two second reinforcing skins wherein said reinforcing fibers of each of said second reinforcing skins are unidirectional with said longitudinal axis of said reinforcing fibers orientated in one direction, said two second reinforcing skins are positioned so that said longitudinal axis of said reinforcing fibers of one of said second reinforcing skins is at an angle to said longitudinal axis of the other one of said second reinforcing skins creating a bi-directional orientation of said reinforcing fibers of said second reinforcing skins. 10. A method in accordance with claim 8 wherein each first and second reinforcing skin comprises between about 50 weight percent and about 80 weight percent of reinforcing fibers. 11. A method in accordance with claim 8 wherein the core layer comprises about 20 weight percent to about 80 weight percent reinforcing fibers. 12. A method in accordance with claim 8 wherein said reinforcing fibers in said core and said first and second reinforcing skins comprise at least one of metal fibers, metalized inorganic fibers, metalized synthetic fibers, glass fibers, polyester fibers, polyamide fibers, graphite fibers, carbon fibers, ceramic fibers, mineral fibers, basalt fibers, inorganic fibers, aramid fibers, kenaf fibers, jute fibers, flax fibers, hemp fibers, cellulosic fibers, sisal fibers, and coir fibers. 13. A method in accordance with claim 8 further comprising bonding at least one decorative layer to the multi-layered fiber reinforced sheet.
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이 특허에 인용된 특허 (13)
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