COMPOSITE LAMINATE RESIN AND FIBERGLASS STRUCTURE

Abstract

A structure comprising a composite laminate resin and fiberglass panel and method of manufacture thereof is provided.

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 layer including uni-directional structural tape of woven glass/thermoplastic composites; 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 composites, said top and bottom layers are sealed to said core.

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

3. The composite laminate structure of claim 2 wherein the core includes a needle punched matte.

4. The composite laminate structure of claim 2 wherein the core includes a thermally treated matte.

5. The composite laminate structure of claim 2 wherein the core has an area weight of 100 to 2500 g/m2 and a thickness from 0.5 to 6 mm.

6. The composite laminate structure of claim 2 wherein the top and bottom layers are heat-fused to the non-woven thermoplastic/fiberglass mix matte.

7. The composite laminate structure of claim 2 wherein the core includes thermoplastic and reinforcing fibers supplied in the form of multi-fiber strands.

8. The composite laminate structure of claim 7 wherein multi-fiber strands are carded so that, there are few unopened and partially opened strands and the matte has a homogenous appearance.

9. The composite laminate structure of claim 8 wherein the carded matte has a lofty appearance prior to sealing with said top and bottom layers.

10. The composite laminate structure of claim 1 wherein said top and bottom layers uni-directional continuous composites are oriented perpendicular to one another.

11. A method of manufacturing a composite laminate structure including the steps of: providing a core of non-woven thermoplastic/fiberglass mix matte; providing a top layer said top layer including continuous 0-90 fiberglass reinforced thermoplastic; locating said top layer on one side of said core; providing a bottom layer, said bottom layer including continuous 0-90 fiberglass reinforced thermoplastic; locating said bottom layer on a side of said core opposite said top layer; and sealing said top and bottom layers to said core.

12. The method of manufacturing a composite laminate structure as set forth in claim 11 wherein said top layer includes uni-directional structural tape of woven glass/thermoplastic composites.

13. The method of manufacturing a composite laminate structure as set forth in claim 12 wherein said bottom layer includes uni-directional structural tape of woven glass/thermoplastic composites.

14. The method of manufacturing a composite laminate structure as set forth in claim 13 including the step of needle punching said core prior to sealing to said top and bottom layers.

15. The method of manufacturing a composite laminate structure as set forth in claim 13 including the step of thermally treating said matte prior to sealing to said top and bottom layers.

16. The method of manufacturing a composite laminate structure as set forth in claim 13 wherein the core has an area weight of 100 to 2500 g/m2 and a thickness from 0.5 to 6 mm.

17. The method of manufacturing a composite laminate structure as set forth in claim 13 including the step of heat fusing said top and bottom layers to said non-woven thermoplastic/fiberglass mix matte.

18. The method of manufacturing a composite laminate structure as set forth in claim 13 including the steps of supplying thermoplastic and reinforcing fibers in the form of multi-fiber strands, blending the multi-fiber strands in an air stream, and depositing the multi-fiber strands on a moving belt,

19. The method of manufacturing a composite laminate structure as set forth in claim 13 including the steps of carding multi-fiber strands to reduce unopened and partially opened strands and providing the matte in a homogenous appearance.

20. The method of manufacturing a composite laminate structure as set forth in claim 13 including the step of orienting said uni-directional fiberglass reinforced thermoplastic in said top and bottom layers perpendicular to one another.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0020] 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:

[0021] FIG. 1 is an exploded perspective view of a composite laminate resin and fiberglass structure in accordance with one embodiment of the subject invention; and

[0022] FIG. 2 is a side view of the composite laminate resin and fiberglass structure of FIG. 1 and an assembled condition.

[0023] 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

[0024] 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.

[0025] 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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

[0030] 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.