Method of making a sandwich-type, compression-molded, composite component having a cellulose-based core and improved surface appearance
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B29C-043/18
B29C-070/46
B29K-023/00
B29L-007/00
B29C-043/10
B29C-043/56
출원번호
US-0603430
(2015-01-23)
등록번호
US-9707725
(2017-07-18)
발명자
/ 주소
Preisler, Darius J.
Heikkila, Christopher A.
출원인 / 주소
Global IP Holdings, LLC
대리인 / 주소
Brooks Kushman P.C.
인용정보
피인용 횟수 :
2인용 특허 :
110
초록▼
A method of making a sandwich-type, compression-molded, composite component having improved surface appearance is provided. Reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core of a blank or stack of sandwich materials are heated to a softening
A method of making a sandwich-type, compression-molded, composite component having improved surface appearance is provided. Reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core of a blank or stack of sandwich materials are heated to a softening temperature of the thermoplastics. The heated blank or stack is allowed to cool in the mold cavity until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal core cavities. Air in the sealed cavities urges softened portions of the sheets and portions of the core inwardly towards the cavities of the core as the air in the cavities cools to inhibit debossing and improve surface appearance of a first outer surface of the blank or stack.
대표청구항▼
1. A method of making a sandwich-type, compression-molded, composite component having improved surface appearance, the method comprising: heating a blank or stack of sandwich material including first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a c
1. A method of making a sandwich-type, compression-molded, composite component having improved surface appearance, the method comprising: heating a blank or stack of sandwich material including first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core positioned between the skins and between the sheets and having a plurality of cavities, the skins, the sheets and the core being heated to a softening temperature of the thermoplastics;providing a compression mold including component-forming, upper and lower dies with opposing molding surfaces cooperating to define a mold cavity having a shape substantially corresponding to a desired shape of the component;placing the blank or stack on the lower die in an open position of the mold;moving the dies toward each other until the mold is in a closed position; andallowing the heated blank or stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal the core cavities, air in the sealed cavities urging softened portions of the sheets and portions of the core inwardly towards the cavities of the core as the air in the cavities cools; andapplying a vacuum at the first outer surface of the blank or stack in the mold cavity sufficient to prevent debossing and improve appearance of the first outer surface during the step of allowing. 2. The method as claimed in claim 1, wherein the first outer surface is an A-surface. 3. The method as claimed in claim 1, further comprising sealing the mold cavity from the surrounding atmosphere during the step of applying. 4. The method as claimed in claim 1, further comprising applying a vacuum at a second outer surface of the stack or blank in the mold cavity to prevent debossing and improve appearance of the second outer surface during the step of allowing. 5. The method as claimed in claim 1, wherein the core is a cellular core. 6. The method as claimed in claim 5, wherein the cellular core is a honeycomb core. 7. The method as claimed in claim 1, wherein each of the skins is fiber reinforced. 8. The method as claimed in claim 1, wherein the thermoplastic of the skins is polypropylene. 9. The method as claimed in claim 1, wherein the component has a thickness in the range of 5 to 25 mm. 10. The method as claimed in claim 1, wherein at least one of the skins is a woven skin. 11. The method as claimed in claim 1, wherein the step of heating is performed outside the mold. 12. A method of making a sandwich-type, compression-molded, composite component having improved surface appearance and for use in a vehicle, the method comprising: heating a blank or stack of sandwich material including first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core positioned between the skins and between the sheets and having a plurality of cavities, the skins, the sheets and the core being heated to a softening temperature of the thermoplastics;providing a compression mold including component-forming, upper and lower dies with opposing molding surfaces cooperating to define a mold cavity having a shape substantially corresponding to a desired shape of the component;placing the blank or stack on the lower die in an open position of the mold;moving the dies toward each other until the mold is in a closed position; andallowing the heated blank or stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal the core cavities, air in the sealed cavities urging softened portions of the sheets and portions of the core inwardly towards the cavities of the core as the air in the cavities cools; andapplying a vacuum at the first outer surface of the stack or blank in the mold cavity sufficient to prevent debossing and improve appearance of the first outer surface during the step of allowing. 13. The method as claimed in claim 12, wherein the first outer surface is an A-surface. 14. The method as claimed in claim 12, further comprising sealing the mold cavity from the surrounding atmosphere during the step of applying. 15. The method as claimed in claim 12, further comprising applying a vacuum at a second outer surface of the stack or blank in the mold cavity to prevent debossing and improve appearance of the second outer surface during the step of allowing. 16. A method of making a sandwich-type, compression-molded, composite component having improved surface appearance for use in the interior of a vehicle, the method comprising: heating a blank or stack of sandwich material including first and second reinforced thermoplastic skins, first and second sheets of thermoplastic adhesive and a cellulose-based core positioned between the skins and between the sheets and having a plurality of cavities, the skins, the sheets and the core being heated to a softening temperature of the thermoplastics;providing a compression mold including component-forming, upper and lower dies with opposing molding surfaces cooperating to define a mold cavity having a shape substantially corresponding to a desired shape of the component;placing the blank or stack on the lower die in an open position of the mold;moving the dies toward each other until the mold is in a closed position; andallowing the heated blank or stack to cool in the mold cavity in the closed position until inner surfaces of the skins are bonded to top and bottom surfaces of the core by the sheets to seal the core cavities, air in the sealed cavities urging softened portions of the sheets and portions of the core inwardly towards the cavities of the core as the air in the cavities cools; andapplying a vacuum at the first outer surface of the stack or blank in the mold cavity sufficient to prevent debossing and improve appearance of the first outer surface during the step of allowing. 17. The method as claimed in claim 16, further comprising applying a vacuum at a second outer surface of the stack or blank in the mold cavity to prevent debossing and improve appearance of the second outer surface during the step of allowing.
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