COMPOSITE LAMINATE RESIN AND FIBERGLASS STRUCTURE

Abstract

A composite laminate structure comprising a core of non-woven thermoplastic/fiberglass mix matte, a top layer located on one side of said core, said top including uni-directional structural tape of woven glass/thermoplastic; and a bottom layer, on a side of said core opposite said top layer, said bottom layer including uni-directional structural tape of woven glass/thermoplastic, said top and bottom layers being heat-fused to said core.

Claims

1. A composite laminate structure comprising: a core of non-woven thermoplastic/fiberglass mix matte; a top layer located on one side of said core, said top including uni-directional structural tape of woven glass/thermoplastic; and a bottom layer, on a side of said core opposite said top layer, said bottom layer including uni-directional structural tape of woven glass/thermoplastic, said top and bottom layers being heat-fused to said core.

2. The composite laminate structure of claim 1, wherein said top and bottom exterior layers include continuous 0-90 fiberglass reinforced thermoplastic.

3. The composite laminate structure of claim 1, wherein the composite has a thickness of from about 0.05 inches to about 1 inch.

4. The composite laminate structure of claim 1, wherein the composite has a coefficient of thermal expansion of from about 3.0E-06 to about 10.0E-06 in as measured by ASTM D6341.

5. The composite laminate structure of claim 1, wherein the composite has a strain at 1,000 psi of from about 0.05% to about 0.3%, or even from about 0.1% to about 0.2% as measured by ASTM D3039-08.

6. The composite laminate structure of claim 1, wherein the composite has a strain at 2,500 psi of from about 0.1% to about 0.7%, or even from about 0.3% to about 0.5% as measured by ASTM D3039-08.

7. The composite laminate structure of claim 1, wherein the composite has an ultimate strength of about 8,000 psi to about 20,000 psi, or even about 10,000 psi to about 17,000 psi as measured by ASTM D3039-08.

8. The composite laminate structure of claim 1, wherein the composite has a density of about 30 lb/ft.sup.3 to about 50 lb/ft.sup.3, or even about 35 lb/ft.sup.3 to about 40 lb/ft.sup.3 as measured by ASTM D1622.

9. The composite laminate structure of claim 1, wherein the composite has a burn rate of about 0.1 to about 1 inch/minute.

10. The composite laminate structure of claim 1, wherein the thermoplastic material is selected from polyethylene, polyamide, acrylic, polyester, polystyrene or polypropylene.

11. The composite laminate structure of claim 1, wherein the fibers have a length of at least about 1 cm, 3 cm or even 5 cm.

12. The composite laminate structure of claim 1, wherein the fibers have an average diameter of about 1 to about 50 microns, or even about 5 to about 25 microns.

13. The composite laminate structure of claim 1, wherein the heat is applied by a laminating process.

14. The composite laminate structure of claim 1, wherein the heat is applied by a molding process.

15. The composite laminate structure of claim 1, wherein the composite includes a honeycomb, foam or pre-preg layer.

16. The composite laminate structure of claim 1, wherein the fibers are oriented in a consistent repeated pattern in one or more layers of the composite.

17. The composite laminate structure of claim 1, wherein the fibers are randomly distributed in one or more layers of the composite.

18. The composite laminate structure of claim 1, wherein the structure is formed under time and pressure on a belt laminator.

19. A composite laminate structure comprising: a core having a Continuous Fiber Reinforced Thermoplastic (CFRT) oriented in a very specific fiber direction; and top and bottom layers of non-carded, non-needle punched hybrid matte consisting of polypropylene/fiberglass reinforcement/thermoset binders.

20. The composite laminate structure of claim 19, wherein the thermoplastic material is selected from polyethylene, polyamide, acrylic, polyester, polystyrene, polypropylene, or any combination thereof.

21. The composite laminate structure of claim 19, wherein the thermoset material is selected from polyurethane, epoxy, methacrylate, silicone, phenolic resin, polyester, or any combination thereof.

22. The composite laminate structure of any of claim 19, wherein the CFRT includes a plurality of fibers selected from glass fibers, carbon fibers, natural fibers or any combination thereof.

23. The composite laminate structure of any of claim 19, wherein the CFRT includes a plurality of fibers having a length of at least about 1 cm, 3 cm or even 5 cm.

24. The composite laminate structure of any of claim 19, wherein the CFRT includes a plurality of fibers having a length of at least about 1 cm, 3 cm or even 5 cm.

25. Use of the composite laminate structure of claim 1 as a wall or floor structure in a commercial vehicle.

26. Use of the composite laminate structure of claim 1 as a material for building construction.

27. Use of the composite laminate structure of claim 1 as a transportation vehicle panel.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The above-mentioned and other features and objects of this invention and the manner of obtaining them will become more apparent and the invention itself will be better understood by reference to the following description of embodiments of the present invention taken in conjunction with the accompanying drawings, wherein:

[0028] FIG. 1 is an exploded perspective view of a composite laminate resin and fiberglass structure in accordance with one embodiment of the subject invention;

[0029] FIG. 2 is a side view of the composite laminate resin and fiberglass structure of FIG. 1 and an assembled condition; and

[0030] FIG. 3 is a side view of another embodiment of the invention.

[0031] Corresponding reference characters indicate corresponding parts if there are more than one view. Although the drawing(s) represent an embodiment of the present invention, the drawing(s) are not necessarily to scale and certain features may be exaggerated in order to better illustrate and explain the present invention. The exemplification set out herein illustrates an embodiment of the invention, and such exemplifications are not to be construed as limiting the scope of the invention in any manner.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

[0032] The explanations and illustrations presented herein are intended to acquaint others skilled in the art with the invention, its principles, and its practical application. Accordingly, the specific embodiments of the present disclosure as set forth are not intended as being exhaustive or limiting. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled. The disclosures of all articles and references, including patent applications and publications, are incorporated by reference for all purposes. Other combinations are also possible as will be gleaned from the following claims, which are also hereby incorporated by reference into this written description.

[0033] For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawing(s), which are described below. It will nevertheless be understood that no limitation of the scope of the invention is thereby intended. The invention includes any alterations and further modifications in the illustrated devices and described methods and further applications of the principles of the invention, which would normally occur to one skilled in the art to which the invention relates.

[0034] The composite structures described herein may include one or more fiber components. The one or more fiber components may be non-woven or woven fibers. The fibers may form a scrim, a mat, a patch or some combination thereof. The fibers may be continuous fibers or discontinuous short fibers. The fibers may be polymeric fibers. The fibers may be glass fibers. The fibers may be carbon fibers. The fibers may be organic or inorganic fibers.

[0035] The fibers may be imbedded in a secondary material or resin. The secondary material may be a thermoplastic material. The secondary material may be a thermoset material. The secondary material may be a polymeric material. The secondary material may be a polyethylene-based material. The secondary material may be a polyamide-based material. The secondary material may include one or more of acrylics, polyesters, polystyrenes or polypropylene. The secondary material may include polyurethane, epoxy, methacrylate, rubber, silicone, phenolic resin or some combination thereof.

[0036] Each fiber may comprise a plurality of different materials. Each fiber may comprise a first material substantially surrounded by a second material. Each fiber may comprise a single material. One or more fibers of different materials may be combined to form a fiber layer of the composite. The fibers may be selected to act as reinforcing fibers. The fibers may be selected to melt at a specified temperature to act as a binder. The fibers may be selected to have adhesive capabilities when exposed to a stimulus (e.g., heat, UV light, or the like). The fiber layer may be described as a core layer.

[0037] The fibers may be utilized to form a skin layer (e.g., a top and/or bottom layer). The fibers may be integrated into a thermoplastic material. The fibers may be integrated into an adhesive material. The fibers may be integrated into a tape material. The fibers may be included a reinforced thermoplastic panel. Such reinforcing fibers may be continuous and extend along an entirety of the panel. Alternatively, the fibers may be located at only certain locations along a panel to provide selected reinforcement at such locations.

[0038] The fibers may be utilized as single strand filaments or may be multi-fiber strands. The fibers may be selected to all have similar lengths or may be selected to have differing lengths. It is possible that the fibers for forming one layer of the composite may be short discontinuous fibers whereas the fibers for forming a second layer of the composite may be long continuous fibers.

[0039] The fibers may have a length of at least about 1 cm, 3 cm or even 5 cm or longer. The fibers may have an average diameter of about 1 to about 50 microns (e.g., about 5 to about 25 microns). The fibers may have a suitable coating located thereon, which may increase the diameter of the fibers. The fibers may be present in one or more layers of the composite in an amount of at least about 10%, 20%, 30% or even 50% by weight. The fibers may be present in one or more layers of the composite in an amount below about 90%, 80%, or even below about 70%, by weight. By way of example, the fibers may be present in each layer, in an amount of about 20% to about 70% by weight. Fiber contents by weight may be determined in accordance with ASTM D2584-11.

[0040] The ratio of fibers (weight percent) to secondary material (in a single layer of the composite or in the entirety of the composite) may be from about 1:40 to about 40:1. The ratio of fibers to secondary material may be from about 1:20 to about 20:1. The ratio of fibers to secondary material may be from about 1:10 to about 10:1. The ratio of fibers to secondary material may be from about 1:2 to about 2:1. The ratio may be selected to maximize coverage of the fibers by the secondary material.

[0041] One or more layers of the composite structure may be formed from a honeycomb material, a pre-preg material, a foam material or combinations thereof. One or more layers may be formed of a plurality of fibers imbedded in a matrix material (which may be the secondary material). The matrix material may be a thermoplastic material. The matrix material may be a thermoset material.

[0042] One or more layers may remain in direct planar contact with an adjacent layer, but without the use of any adhesive or additional fastening means. Alternatively, one or more layers may include an adhesive material or a material that has adhesive qualities at certain predetermined temperatures. For example, the composite structure may be located into a mold or laminating device where it may experience increased temperatures that cause one or more materials within the composite to rise above their respective glass transition temperatures (Tg). This may cause adhesion between one or more layers of the composite material. It is also possible that the one or more layers include a metallic component so that an induction heating process may be utilized to raise the temperature of one or more components of the composite layers. It is also possible that one or more layers are formed from a tape material. Such tape material may include a single side or multiple sides having adhesive capability. The tape may be a pressure sensitive material that adheres upon exposure to a predetermined amount of pressure.

[0043] The composite may include only two layers. The composite may include only three layers. The composite may include only four layers. The composite may include only five layers.

[0044] Now referring to FIGS. 1 and 2, a multi-layer fiberglass reinforced thermoplastic composite or structure, designed for lightweight composite panel applications, is disclosed and shown generally indicated in an exploded view as 10.

[0045] The core material consists of a needle punched and/or thermally treated, non-woven thermoplastic/fiberglass mix matte, generally indicated as 12. In one method of making such a thermoplastic/fiberglass mix matte, the thermoplastic and reinforcing fibers can be supplied in the form of multi-fiber strands, blended in an air stream, and deposited on a moving belt. The fibers, which at this stage can be in the form of strands, partially opened strands, and fibers, can be subjected to one or more carding operations. Following carding, the number of unopened and partially opened strands is low, so that the mat appears to be relatively homogenous. Following needling, a very homogenous appearance is achieved, with virtually no strands observable to the eye. The mat product is lofty. The fibers can be long or short as is known in the art. In one embodiment, the core material 12 has an area weight of 100 to 2500 g/m2 and a thickness from 0.5 to 6 mm.

[0046] The core material 12 is sandwiched between top and bottom layers, generally indicated as 14, 16, respectively. In a preferred embodiment, good strength is achieved through the use of continuous 0-90 fiberglass reinforced thermoplastic composite skins as top and bottom layers 14 and 16. In particular, uni-directional structural tape of woven glass/thermoplastic composites can be used for top and bottom layers.

[0047] In one method of manufacturing the multi-layer fiberglass reinforced thermoplastic composite or structure 10, the skins or top and bottom layers 14, 16 are heat-fused to lightweight fiberglass reinforced thermoplastic non-woven, needled-punched core 12. This creates an I-Beam type composite that is lightweight yet stiff.

[0048] The construct 10 displays excellent impact strength and flexural stiffness, while using a lightweight construct. The core density, resin to fiber reinforcement ratio, fiber placement, fiber size/type and core thickness can be tailored to meet desired mechanical properties. Furthermore, the skin density, resin to fiber reinforcement ratio, fiber placement/alignment, fiber size/type and skin thickness can be tailored to meet different mechanical properties.

[0049] Now referring to FIG. 3, another embodiment of a novel construct is shown generally indicated as 110, whereby different layers of materials are combined in precise ways to then be put through a belt-laminator or heated by other means such as infrared, thereby creating a single composite construct that can then be used in many ways. This resultant construct can be heat molded to create specific shapes that are both lighter and tougher than tradition materials or can be used as a strength adding component layer in other constructs. The construct is novel in both the material used as well as the actual configuration of the layers. The uniqueness of the configuration is in the numbers/materials of layers used, the order in which the component layers are stacked up and the time/pressure the construct is in the belt-laminator, if such is used.

[0050] The primary layers in the construct 110 stack can include a non-carded, non-needle punched hybrid matte consisting of polypropylene/fiberglass reinforcement/thermoset binders, (which may be known as Material-X); a Continuous Fiber Reinforced Thermoplastic (CFRT) oriented in a very specific fiber direction; woven or knitted fiber mats made of fiberglass, carbon fiber, natural fibers, etc.; and/or other types of fibrous/PP mats with fibers of varying lengths oriented in a randomized fashion.

[0051] In particular, one example of a construct 110, which can be used as an automotive under-body shield among other things, includes a core layer of a Continuous Fiber Reinforced Thermoplastic (CFRT) which is shown generally indicated as 112 in FIG. 3. Core CFRT layer 112 is sandwiched between two layers of a non-carded, non-needle punched hybrid matte consisting of polypropylene/fiberglass reinforcement/thermoset binders (MaterialX), which are generally indicated as a top layer 114 and a bottom layer 116.

[0052] The advantages and novelty of construct 110 include but are not limited to: Material-X top and bottom layers, 114 and 116, respectively provide finished surface layers and adds mass to the composite. Also, Material-X is a hybrid matte consisting of polypropylene/fiberglass reinforcement/thermoset binders. The polypropylene adds formability and ductility, the glass reinforcement adds stiffness, and the thermoset binder provides higher heat deflection, additional fiber wet-out, and stiffness. The Continuous Fiber Reinforced Thermoplastic (CFRT) adds structure, rigidity, and impact strength. These materials combined into layers create an ultra-high strength composite with excellent durability and low weight. This construct differs vastly from typical non-woven glass/polypropylene molded composites used throughout the industry today.

[0053] In other embodiments, the woven or knitted fiber mats made of fiberglass, carbon fiber, natural fibers, etc.; and/or other types of fibrous/PP mats with fibers of varying lengths oriented in a randomized fashion may be substituted for core layer 112 or either one or both added in as additional layers in the laminate.

[0054] To produce Material-X, it can be formed as a wet layered matt comprising a slurry with water that is formed on a chain with the fiberglass and polypropylene added in and then dried and rolled up. The construct may be heat activated in a belt laminator using temperatures, for example, in the 100 to 300 C. range or may be heated using infrared or other heating techniques. The pressure applied to the laminate can be very low or no pressure, such as when just heating by infrared to activate the thermoset binders, or pressures up to about 20 bars may be applied using a belt-laminator.

[0055] The overall approach of the subject invention varies vastly from typical constructs. The continuous glass combined with the non-woven and thermoset binders create a much more durable solution with lower overall panel weight than presently known panels.

[0056] The composite materials described herein also have additional physical properties that provide for improved performance, while also minimizing manufacturing challenges. Samples of various materials as described herein are subjected to a variety of tests for determining certain physical characteristics. The following tensile properties in Tables 1 and 2 below are measured in accordance with ASTM D3039-08. The densities as shown in Table 3 are measured in accordance with ASTM D1622. The linear coefficients of thermal expansion as shown in Tables 4 and 5 are measured in accordance with ASTM D6341-10.

TABLE-US-00001 TABLE 1 Chord Strain at Strain at Modulus of Ultimate Ultimate Specimen Width Thickness 1000 psi 2500 psi Elasticity load Strength Failure No. (in) (in) (%) (%) (psi) (lbf) (psi) mode D1 1.021 0.192 0.15 0.37 6.74E+05 2240 11400 L, M, V D2 1.018 0.184 0.17 0.43 5.89E+05 2570 13700 L, M, V D3 1.019 0.184 0.15 0.37 6.85E+05 2410 12900 L, M, V D4 1.012 0.195 0.13 0.33 7.49E+05 2700 14400 L, M, V D5 1.011 0.185 0.13 0.33 7.59E+05 2870 15300 G, A, T Average 1.016 0.186 0.15 0.36 6.91E+05 2558 13500

TABLE-US-00002 TABLE 2 Chord Strain at Strain at Modulus of Ultimate Ultimate Specimen Width Thickness 1000 psi 2500 psi Elasticity load Strength Failure No. (in) (in) (%) (%) (psi) (lbf) (psi) mode E1 1.003 0.198 0.13 0.34 7.48E+05 3230 16300 L, M, V E2 0.990 0.192 0.14 0.35 7.25E+05 3090 16300 L, W, B E3 1.003 0.197 0.14 0.34 7.25E+05 3150 15900 L, W, B E4 1.002 0.198 0.13 0.33 7.46E+05 3250 16400 L, A, T E5 1.003 0.186 0.15 0.37 6.76E+05 2680 14400 L, A, B Average 1.000 0.194 0.14 0.35 7.24E+05 3080 15900 Failure codes: LLateral Failure Line; SLongitudinal Splitting Failure Line; GGage Area; AAt Grip/Tab; MMiddle; BBottom; TTop

TABLE-US-00003 TABLE 3 Weight Specimen Thickness Width Length Mass Volume per ft.sup.2 Density No. (in) (in) (in) (g) (in.sup.3) (lb/ft.sup.2) (lb/ft.sup.3) D1 0.187 5.986 5.987 67.380 6.70 0.5969 38.3 D2 0.189 5.996 5.980 65.710 6.78 0.5818 36.94 D3 0.191 5.995 5.990 66.340 6.86 0.5865 36.85 E1 0.198 6.017 6.015 68.250 7.17 0.5987 36.28 E2 0.198 6.018 6.012 69.810 7.16 0.6126 37.12 E3 0.195 5.998 6.018 69.330 7.04 0.6098 37.52

TABLE-US-00004 TABLE 4 Sample Temp Humidity Length Length Length Length Length Type ( F.) (%) (in) D1 (in) D2 (in) D3 (in) D4 (in) D5 D 30 N/A 11.861 11.861 11.860 11.864 11.871 D 73 50 11.867 11.869 11.867 11.870 11.881 D 140 49 11.870 11.871 11.868 11.873 11.883 .sup.1(in/in)/ F. 4.35E06 4.76E06 4.44E06 4.67E06 6.48E06 Average Coefficient of Thermal Expansion ((in/in)/ F.): 4.94E06

TABLE-US-00005 TABLE 5 Sample Temp Humidity Length Length Length Length Length Type ( F.) (%) (in) E1 (in) E2 (in) E3 (in) E4 (in) E5 E 30 N/A 11.978 11.972 11.975 11.975 11.928 E 73 49 11.987 11.981 11.984 11.982 11.935 E 140 49 11.989 11.989 11.985 11.985 11.935 .sup.1(in/in)/ F. 5.56E06 4.23E06 4.98E06 3.60E06 3.77E06 Average Coefficient of Thermal Expansion ((in/in)/ F.): 4.43E06

TABLE-US-00006 TABLE 6 Coefficient Ultimate of Thermal Pass/Fail Strength Modulus Density Expansion Burn test (psi) of Weight (lb/ft.sup.3) (in/in)/ F. Burn (pass = (ASTM Elasticity per ft.sup.2 (ASTM (ASTM Rate less than Sample D3039-08) (psi) (lb/ft.sup.2) D1622) D6341) (in/min) 4 in/min) A (poly 11.100 6.25E+05 0.5945 33.35 5.07E06 0.78 Pass fiberglass) B (tape 1) 14.600 7.31E+05 0.5844 37.04 3.41E06 0.45 Pass C (tape 2) 12.300 7.75E+05 0.5727 40.35 4.13E06 0.96 Pass D (sample + 13.500 6.91E+05 0.5884 37.36 4.94E06 0.31 Pass tape 2) E (sample + 15.900 7.24E+05 0.6070 36.98 4.43E06 0.35 Pass tape 1)

[0057] Parts by weight as used herein refers to 100 parts by weight of the composition specifically referred to. Any numerical values recited in the above application include all values from the lower value to the upper value in increments of one unit provided that there is a separation of at least 2 units between any lower value and any higher value. As an example, if it is stated that the amount of a component or a value of a process variable such as, for example, temperature, pressure, time and the like is, for example, from 1 to 90, preferably from 20 to 80, more preferably from 30 to 70, it is intended that values such as 15 to 85, 22 to 68, 43 to 51, 30 to 32 etc. are expressly enumerated in this specification. For values which are less than one, one unit is considered to be 0.0001, 0.001, 0.01 or 0.1 as appropriate. These are only examples of what is specifically intended and all possible combinations of numerical values between the lowest value, and the highest value enumerated are to be considered to be expressly stated in this application in a similar manner. Unless otherwise stated, all ranges include both endpoints and all numbers between the endpoints. The use of about or approximately in connection with a range applies to both ends of the range. Thus, about 20 to 30 is intended to cover about 20 to about 30, inclusive of at least the specified endpoints. The term consisting essentially of to describe a combination shall include the elements, ingredients, components or steps identified, and such other elements ingredients, components or steps that do not materially affect the basic and novel characteristics of the combination. The use of the terms comprising or including to describe combinations of elements, ingredients, components or steps herein also contemplates embodiments that consist essentially of the elements, ingredients, components or steps. Plural elements, ingredients, components or steps can be provided by a single integrated element, ingredient, component or step. Alternatively, a single integrated element, ingredient, component or step might be divided into separate plural elements, ingredients, components or steps. The disclosure of a or one to describe an element, ingredient, component or step is not intended to foreclose additional elements, ingredients, components or steps.

[0058] While the invention has been taught with specific reference to these embodiments, one skilled in the art will recognize that changes can be made in form and detail without departing from the spirit and scope of the invention. Therefore, the described embodiments are to be considered in all respects only as illustrative and not restrictive. As such, the scope of the invention is indicated by the following claims rather than by the description.