Lightweight thermoplastic composite including bi-directional fiber tapes
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B32B-005/00
B32B-005/26
출원번호
US-0002518
(2007-12-14)
등록번호
US-8568853
(2013-10-29)
발명자
/ 주소
Raghavendran, Venkat
Smith, Gary Francis
출원인 / 주소
Hanwha Azdel, Inc.
대리인 / 주소
Rhodes IP PLC
인용정보
피인용 횟수 :
2인용 특허 :
0
초록▼
A fiber reinforced thermoplastic composite having an improved combination of flexural, impact, and heat distortion characteristics. The composite comprises a fiber reinforced thermoplastic core containing fibers bonded together with a first thermoplastic resin in which the core has a first surface a
A fiber reinforced thermoplastic composite having an improved combination of flexural, impact, and heat distortion characteristics. The composite comprises a fiber reinforced thermoplastic core containing fibers bonded together with a first thermoplastic resin in which the core has a first surface and a second surface and at least one first skin applied to the first surface. The first skin comprises one or more bi-directional continuous fiber tapes having a plurality of continuous fibers bonded together with one or more thermoplastic resins. The fibers in each first skin are arranged in a first and a second direction, with the fibers in each direction being unidirectionally oriented within the skin. Bi-directional orientation of the continuous fiber tapes is present in at least one of the tapes, or is achieved through the use of two or more tapes having unidirectional continuous fibers.
대표청구항▼
1. A non-porous fiber reinforced composite having an improved combination of flexural, impact, and heat distortion temperature characteristics, comprising: a fiber reinforced thermoplastic core comprising a plurality of reinforcing fibers bonded together with one or more first thermoplastic resins,
1. A non-porous fiber reinforced composite having an improved combination of flexural, impact, and heat distortion temperature characteristics, comprising: a fiber reinforced thermoplastic core comprising a plurality of reinforcing fibers bonded together with one or more first thermoplastic resins, said core comprising a first surface and a second surface; anda plurality of first skins applied to said first surface, wherein said first skins are bonded to each other,wherein each said first skin comprises one or more bi-directional continuous fiber tapes comprising a plurality of continuous fibers arranged in a first principal direction and a plurality of continuous fibers arranged in a second principal direction and one or more second thermoplastic resins impregnated with the bi-directional continuous fiber tape, the plurality of continuous fibers in each said first principal direction and said second principal direction being independently arranged in a corresponding first and second unidirectional orientation; andwherein, the composite demonstrates an improved combination of flexural, impact, and heat distortion temperature properties at reduced fiber content in the thermoplastic core; andwherein, the flexural modulus of the composite is greater than about 2000 MPa and the flexural strength is greater than about 15 MPa; andwherein, the impact energy is greater than about 11 J. 2. The fiber reinforced composite of claim 1, wherein the bi-directional continuous fiber tape comprises one or more first unidirectional tapes having a plurality of continuous fibers arranged in the first principal direction and one or more second unidirectional tapes having a plurality of continuous fibers arranged in the second principal direction, the first and second unidirectional tapes being independently impregnated with the one or more second thermoplastic resins that are the same or different. 3. The fiber reinforced composite of claim 2, wherein the orientation of the first principal direction ranges from about 0 to about 90 degrees relative to the orientation of the second principal direction. 4. The fiber reinforced composite of claim 1, wherein the bi-directional continuous fiber tape formed from a first plurality of continuous fibers arranged in the first principal direction and a second plurality of continuous fibers arranged in the second principal direction, and being impregnated with one or more second thermoplastic resins. 5. The fiber composite of claim 4, wherein the orientation of the first principal direction ranges from about 0 to 90 degrees relative to the orientation of the second principal direction. 6. The fiber reinforced composite of claim 1, wherein the bi-directional continuous fiber tape comprises a bulk tow mat having a plurality of layers of unidirectional fiber tows, with one or more layers having unidirectional fiber tows arranged in the first principal direction and one or more layers having unidirectional fiber tows arranged in the second principal direction. 7. The fiber reinforced composite of claim 6, wherein the orientation of the first principal direction ranges from about 0 to about 90 degrees relative to the orientation of the second principal direction. 8. The fiber reinforced composite of claim 7, wherein a first layer of unidirectional fiber tows has a first principal direction that differs from the second principal direction of at least one adjacent second layer of unidirectional fiber tows. 9. The fiber reinforced composite of claim 1, wherein an angle defined by a longitudinal axis of said plurality of fibers in one first skin and a longitudinal axis of said plurality of fibers in an adjacent first skin ranges between about 0 degrees to about 90 degrees. 10. The fiber reinforced composite of claim 1, wherein the composite further comprises at least one second skin comprising a plurality of fibers bonded together with a third thermoplastic resin. 11. The fiber reinforced composite of claim 10, wherein the first thermoplastic resin, the second thermoplastic resin, and the third thermoplastic resin are the same or different thermoplastic resin. 12. The fiber reinforced composite of claim 1, wherein the composite comprises a plurality of second skins bonded of the second surface of the core. 13. The fiber reinforced composite of claim 1, wherein the fiber content is between about 20 wt % and about 80 wt % of the composite. 14. The fiber reinforced composite of claim 1, wherein the fiber content is between about 40 wt. % and about 70 wt. % of the composite. 15. The fiber reinforced composite of claim 1, wherein the core comprises about 15 wt. % to about 85 wt. % reinforcing fibers. 16. The fiber reinforced composite claim 1, wherein at least one of the reinforcing fibers in the core and the fibers in each first skin are independently selected from 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, coir fibers, or combinations thereof. 17. The fiber reinforced composite of claim 10, wherein at least one of the reinforcing fibers in the core, the fibers in each first skin, and the fibers in each second skin are independently selected from 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, coir fibers, or combinations thereof. 18. The fiber reinforced composite of claim 1, wherein at least one of the first thermoplastic resin and the second thermoplastic resin is independently selected from polyolefins, thermoplastic polyolefin blends, polyvinyl polymers, butadiene polymers, acrylic polymers, polyamides, polyesters, polycarbonates, polyestercarbonates, polystyrenes, acrylonitrylstyrene polymers, acrylonitrile-butylacrylate-styrene polymers, polyimides, polyphenylene ether, polyphenylene oxide, polyphenylenesulphide, polyethers, polyetherketones, polyacetals, polyurethanes, polybenzimidazole, and copolymers or mixtures thereof. 19. The fiber reinforced composite of claim 10, wherein at least one of the first thermoplastic resin, the second thermoplastic resin, and the third thermoplastic resin is independently selected from polyolefins, thermoplastic polyolefin blends, polyvinyl polymers, butadiene polymers, acrylic polymers, polyamides, polyesters, polycarbonates, polyestercarbonates, polystyrenes, acrylonitrylstyrene polymers, acrylonitrile-butylacrylate-styrene polymers, polyimides, polyphenylene ether, polyphenylene oxide, polyphenylenesulphide, polyethers, polyetherketones, polyacetals, polyurethanes, polybenzimidazole, and copolymers or mixtures thereof. 20. The fiber reinforced composite of claim 1, wherein second thermoplastic resin is impregnated within the bi-directional continuous fiber tape of the first skin by solution processing, slurry processing, melt impregnation, fiber co-mingling, or dry powder impregnation. 21. The fiber reinforced composite of claim 1, wherein the thermoplastic core is prepared by a dry laid or a wet laid method. 22. The fiber reinforced composite of claim 21, wherein the thermoplastic core is prepared by a method comprising, adding reinforcing fibers and a thermoplastic resin to an agitated liquid-containing foam to form a dispersed mixture of thermoplastic resin and reinforcing fibers,depositing the dispersed mixture of reinforcing fibers and thermoplastic resin onto a forming support element;evacuating the liquid to form a web;heating the web above the softening temperature of the thermoplastic resin; andcompressing the web to a predetermined thickness to form the thermoplastic core. 23. The fiber reinforced composite of claim 10, wherein the third thermoplastic resin is impregnated into the fibers of the second skin by solution processing, slurry processing, melt impregnation, fiber co-mingling, or dry powder impregnation. 24. An article formed from the fiber reinforced composite of claim 1.
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