IPC분류정보
국가/구분 |
United States(US) Patent
등록
|
국제특허분류(IPC7판) |
|
출원번호 |
US-0393319
(2006-03-30)
|
등록번호 |
US-8597562
(2013-12-03)
|
발명자
/ 주소 |
- Wang, Chen-Shih
- Kia, Hamid G.
|
출원인 / 주소 |
- GM Global Technology Operations LLC
|
대리인 / 주소 |
|
인용정보 |
피인용 횟수 :
1 인용 특허 :
5 |
초록
▼
A process comprising: placing a preform stack in a cavity of a molding tool; the preform stack comprising a fiber mat, and at least a first veil underlying the fiber mat, and a first resin impregnating at least the fiber mat, and wherein at least a portion of the first resin is cured; injecting a se
A process comprising: placing a preform stack in a cavity of a molding tool; the preform stack comprising a fiber mat, and at least a first veil underlying the fiber mat, and a first resin impregnating at least the fiber mat, and wherein at least a portion of the first resin is cured; injecting a second resin into the cavity of the molding tool and over at least the fiber mat; applying heat and pressure to the preform stack and second resin to cure any uncured portion of the first resin and to cure the second resin to form a composite having a resin layer over the fiber mat as the cosmetic surface.
대표청구항
▼
1. A process comprising: providing a preform stack and a molding tool, opening the molding tool and placing the preform stack in a cavity of the molding tool; the preform stack comprising a fiber mat, at least a first veil underlying the fiber mat, and a first resin impregnating at least the fiber m
1. A process comprising: providing a preform stack and a molding tool, opening the molding tool and placing the preform stack in a cavity of the molding tool; the preform stack comprising a fiber mat, at least a first veil underlying the fiber mat, and a first resin impregnating at least the fiber mat, wherein at least a portion of the first resin is cured, and wherein the at least a first veil comprises a first layer and a second layer underlying the first layer, both of the first and second layers comprising randomly distributed fibers;injecting a second resin into the cavity of the mold and over at least the fiber mat;applying heat and pressure to the preform stack and second resin to cure any uncured portion of the first resin and to cure the second resin to form a composite having a resin layer over the fiber mat. 2. A process as set forth in claim 1 wherein the preform stack further comprises a second veil over the fiber mat. 3. A process as set forth in claim 1 wherein the first veil further comprises a third layer comprising randomly distributed fibers, the third layer of the first veil underlying the second layer of the first veil. 4. A process as set forth in claim 2 wherein the second veil comprises at least a first layer comprising randomly distributed fibers. 5. A process as set forth in claim 1 wherein the first resin comprises at least one of epoxy, vinylester, polyester or polyurethane. 6. A process as set forth in claim 1 wherein the second resin comprises at least one of epoxy, vinylester, polyester or polyurethane. 7. A process as set forth in claim 1 wherein the fiber mat comprises woven fibers. 8. A process as set forth in claim 1 wherein the fiber mat comprises randomly distributed fibers. 9. A process as set forth in claim 1 wherein the fiber mat comprises fibers comprising at least one of glass, carbon, polyester, polyolefin, polyamide or natural fibers. 10. A process as set forth in claim 1 further comprising forming the preform stack comprising providing a fiber reinforcement stack comprising at least a fiber mat, and impregnating the fiber mat with the first resin, and placing the fiber reinforcement stack in a preforming tool and curing at least a portion of the first resin. 11. A process as set forth in claim 10 wherein about 10% to about 80% of the first resin is cured in the preforming tool. 12. A process as set forth in claim 10 wherein the fiber reinforcement stack comprises the first veil underlying the fiber mat. 13. A process as set forth in claim 10 wherein the fiber reinforcement stack comprises the first veil comprising at least the first layer comprising randomly distributed fibers. 14. A process as set forth in claim 13 wherein the first veil further comprises a second layer comprising randomly distributed fibers, the second layer of the first veil underlying the first layer of first veil. 15. A process as set forth in claim 14 wherein the first veil further comprises a third layer of randomly distributed fibers, the third layer of the first veil underlying the second layer of the first veil. 16. A process as set forth in claim 12 further comprising a second veil overlying the fiber mat. 17. A process as set forth in claim 16 wherein the second veil comprises at least a first layer comprising randomly distributed fibers. 18. A process comprising: providing a first reinforcement stack comprising a fiber mat, a first veil underlying the fiber mat, and a second veil overlying the fiber mat;impregnating the fiber reinforcement stack with a first resin;placing the resin impregnated fiber reinforcement stack in a preforming tool and applying heat and pressure to cure at least a portion of the first resin and to provide a preform;removing the preform from the preforming tool and placing the preform in a cavity of a molding tool different than the preforming tool and injecting a second resin into the cavity and at least over the preform, and applying heat and pressure to cure any uncured portion of the first resin and to cure the second resin so that a molded composite panel having a cosmetic surface is produced wherein no fiber is exposed at the cosmetic surface. 19. A process as set forth in claim 1 wherein the placing, injecting and applying are conducted so that a molded composite panel having a cosmetic surface is produced wherein no fiber is exposed at the cosmetic surface. 20. A process as set forth in claim 19 wherein the panel comprises a vehicle body panel. 21. A process comprising: providing a preform stack and a molding tool, opening the molding tool and placing the preform stack in a cavity of the molding tool; the preform stack comprising a fiber mat, at least a first veil underlying the fiber mat, and a first resin impregnating at least the fiber mat, wherein at least a portion of the first resin is cured, and wherein the at least a first veil comprises a first layer and a second layer underlying the first layer, both of the first and second layers comprising randomly distributed fibers wherein the first veil is thinner than the fiber mat;injecting a second resin into the cavity of the mold and over at least the fiber mat;applying heat and pressure to the preform stack and second resin to cure any uncured portion of the first resin and to cure the second resin to form a composite having a resin layer over the fiber mat. 22. A process comprising: providing a first reinforcement stack comprising a fiber mat, a first veil underlying the fiber mat, and a second veil overlying the fiber mat;impregnating the fiber reinforcement stack with a first resin;placing the resin impregnated fiber reinforcement stack in a preforming tool and applying heat and pressure to cure at least a portion of the first resin and to provide a preform;removing the preform from the preforming tool and placing the preform in a cavity of a molding tool different than the preforming tool and injecting a second resin into the cavity and at least over the preform, and applying heat and pressure to cure any uncured portion of the first resin and to cure the second resin so that a molded composite panel having a cosmetic surface is produced wherein no fiber is exposed at the cosmetic surface wherein the second veil comprises layers having a thickness ranging from about 0.05 mm to 0.5 mm. 23. A process as set forth in claim 1 wherein the first veil further comprises glass, carbon, polyester, or cotton fibers. 24. A process as set forth in claim 18 wherein the second veil further comprises glass, carbon, polyester, or cotton fibers.
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