c) the pressed stack is cooled, whereby the planar composite component with consolidated layers integrally bonded to each other is formed.
after the pressing the consolidated core layer(s) has/have an air pore content of <5 vol.-% and the consolidated core layer has an air pore content of 20 to 80 vol-%.
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B29B 13/02 - Conditioning or physical treatment of the material to be shaped by heating
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B32B 37/08 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the cooling method
B32B 37/04 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
B32B 37/18 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of discrete sheets or panels only
B32B 7/02 - Physical, chemical or physicochemical properties
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
A sheetlike composite material including at least one layer A of a nonwoven thermoplastic fiber web or a thermoplastic film, and at least two unidirectional oriented-fiber layers B and B′, the layers B and B′ having a bidirectional fiber orientation. The layers are not only needled but also stitched to one another.
B29C 70/02 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements and fillers incorporated in matrix material, forming one or more layers, with or without non-reinforced or non-filled layers
B29C 39/20 - Making multilayered or multicoloured articles
B29C 43/30 - Making multilayered or multicoloured articles
B29C 51/14 - Shaping by thermoforming, e.g. shaping sheets in matched moulds or by deep-drawingApparatus therefor using multilayered preforms or sheets
B29C 70/24 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in at least three directions forming a three dimensional structure
B29C 70/50 - Shaping or impregnating by compression for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
B32B 5/10 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer reinforced with filaments
B32B 5/12 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by the relative arrangement of fibres or filaments of adjacent layers
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B32B 38/00 - Ancillary operations in connection with laminating processes
D04H 1/46 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres
D04H 1/48 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation
3.
METHOD OF MANUFACTURING A COMPOSITE PART COMPRISING A CORE AND AT LEAST ONE SKIN REGION
A method of manufacturing a composite part comprising a core (16) and at least one skin region (20, 22) formed of a skin polymer attached thereto, the skin polymer being a low-friction thermoplastic polymer, comprises the following steps: a) providing a mold with a heatable mold cavity; b) loading into the mold cavity a core element having a surface with at least one contacting region provided with a plurality of anchoring sites (10), and - previously or subsequently - loading into the mold cavity a layer of the skin polymer in powder form adjacent said contacting region and embedding the anchoring sites; c) applying a heat pressing step whereby the skin polymer powder is molten to form a molten skin polymer matrix (20, 22, 32); d) applying a cooling step, whereby the skin polymer matrix solidifies to form a skin region mechanically engaged into the anchoring sites of the core element forming the core. The method allows production of lightweight composite parts with excellent surface properties of the skin region.
B29C 43/00 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor
B29C 43/18 - Compression moulding, i.e. applying external pressure to flow the moulding materialApparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
4.
METHOD FOR PRODUCING A PLANAR COMPOSITE COMPONENT AND COMPOSITE COMPONENT PRODUCED THEREBY
The invention relates to a method for producing a planar composite component having a core layer (B), which is arranged between and integrally bonded to two cover layers (A, A'), the cover layers containing a cover-layer thermoplastic and the core layer containing a core-layer thermoplastic, which method comprises the following steps: a) a heated stack of the layer sequence A-B-A' is provided; b) the heated stack (Α-Β-Α') is pressed; c) the pressed stack is cooled, the planar composite component with consolidated layers integrally bonded to each other being formed. The aim of the invention is to improve the production method including the producibility of planar 3-D components. This aim is achieved, according to the invention, in that at least one of the cover layers (A, A') in unconsolidated form has a fiber nonwoven layer of 10 to 100 wt% of thermoplastic fibers of the cover-layer thermoplastic and 0 to 90 wt% of reinforcing fibers having a weight per unit area of 300 to 3000 g/m2; the core layer (B) in unconsolidated form comprises at least one randomly-oriented-fiber nonwoven layer (D) formed from reinforcing fibers and thermoplastic fibers of the core-layer thermoplastic, and that, after the pressing, the consolidated core layer(s) have an air pore content of ឬ 5 vol% and the consolidated core layer has an air pore content of 20 to 80 vol%.
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
B32B 5/22 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous
B32B 5/24 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B32B 7/02 - Physical, chemical or physicochemical properties
B32B 19/02 - Layered products essentially comprising natural mineral fibres or particles, e.g. asbestos, mica bonded with or embedded in a plastic substance
B32B 19/04 - Layered products essentially comprising natural mineral fibres or particles, e.g. asbestos, mica next to another layer of a specific substance
B32B 19/06 - Layered products essentially comprising natural mineral fibres or particles, e.g. asbestos, mica next to a fibrous or filamentary layer
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B32B 38/00 - Ancillary operations in connection with laminating processes
B32B 1/00 - Layered products having a non-planar shape
B32B 3/00 - Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shapeLayered products comprising a layer having particular features of form
B32B 37/04 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
A planar composite material comprises an UD fiber layer A made of discrete reinforcing fiber rovings and a fiber nonwoven layer B made of a thermoplastic nonwoven which may contain reinforcing fibers, wherein the layers A and B are needled to each other.
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
D04H 1/72 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
D04H 1/732 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged by fluid current, e.g. air-lay
D04H 1/74 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being orientated, e.g. in parallel
D04H 1/498 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres entanglement of layered webs
B29C 70/08 - Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, with or without non-reinforced layers
D04H 3/03 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
D04H 3/04 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
D04H 3/105 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
D04H 5/02 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
D04H 5/03 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
B32B 5/02 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments
B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
B32B 1/00 - Layered products having a non-planar shape
B29C 70/50 - Shaping or impregnating by compression for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
B32B 37/04 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
D04H 1/485 - Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties the fleeces or layers being consolidated by mechanical means, e.g. by rolling by needling or like operations to cause entanglement of fibres in combination with at least one other method of consolidation in combination with weld-bonding
The invention relates to a planar composite material which comprises a UD fibre layer A consisting of discrete reinforcing fibre rovings, and a fibrous nonwoven layer B consisting of a thermoplastic nonwoven fabric that can contain reinforcing fibres, layers A and B being needle-punched together.
D04H 3/04 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
D04H 5/03 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling by fluid jet
D04H 3/10 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically
B29C 70/20 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length oriented in a single direction, e.g. roving or other parallel fibres
D04H 3/03 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments at random
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
B29C 70/08 - Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, with or without non-reinforced layers
D04H 5/02 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
The invention relates to a sheetlike composite material comprising at least one layer A of a nonwoven thermoplastic fibre web or a thermoplastic film, and at least two unidirectional oriented-fibre layers B and B', the layers B and B' having a bidirectional fibre orientation. The layers are not only needled but also stitched to one another.
B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
B32B 5/12 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by the relative arrangement of fibres or filaments of adjacent layers
D04H 3/04 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of forming fleeces or layers, e.g. reorientation of yarns or filaments in rectilinear paths, e.g. crossing at right angles
D04H 3/105 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by needling
D04H 3/115 - Non woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between yarns or filaments made mechanically by applying or inserting filamentary binding elements
D04H 5/02 - Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
B29C 70/16 - Fibrous reinforcements only characterised by the structure of fibrous reinforcements using fibres of substantial or continuous length
B29C 70/40 - Shaping or impregnating by compression
B32B 27/12 - Layered products essentially comprising synthetic resin next to a fibrous or filamentary layer
B32B 27/28 - Layered products essentially comprising synthetic resin comprising copolymers of synthetic resins not wholly covered by any one of the following subgroups
B32B 5/08 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments the fibres or filaments of a layer being specially arranged or being of different substances
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
8.
A COMPOSITE MATERIAL FOR LINING OF AUTOMOTIVE PARTS
The invention relates to a composite material for lining of automotive parts, comprising a carrier layer(A) made of a porous, fiber reinforced polyolefin and a high-gloss decorative skin (B) made of a deep-drawable amorphous thermoplastic, preferably TPO. The thickness of the decorative skin (B) is lower than the thickness of the carrier layer (A).
B32B 7/02 - Physical, chemical or physicochemical properties
B32B 27/08 - Layered products essentially comprising synthetic resin as the main or only constituent of a layer next to another layer of a specific substance of synthetic resin of a different kind
B32B 27/20 - Layered products essentially comprising synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
B60R 19/02 - Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects
B60R 19/03 - Bumpers, i.e. impact receiving or absorbing members for protecting vehicles or fending off blows from other vehicles or objects characterised by material, e.g. composite
The invention relates to a thermoplastically deformable composite material made of a core layer with a glass-fibre-textile ply connected on both sides to a fibre-non-woven ply which comprises polypropylene fibres and glass fibres. There is connection between the core layer and at least one outer layer which comprises polypropylene fibres and polyethylene terephthalate fibres. The invention further relates to a process for producing the material through needling of the individual layers and heating to melt the polypropylene fibres, and also to the use of the material for automobile parts.
B29C 70/08 - Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, with or without non-reinforced layers
B29C 70/34 - Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or coreShaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression
B29C 70/46 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
B29C 70/50 - Shaping or impregnating by compression for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
B32B 5/06 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by structural features of a layer comprising fibres or filaments characterised by a fibrous layer needled to another layer, e.g. of fibres, of paper
B32B 5/26 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by the presence of two or more layers which comprise fibres, filaments, granules, or powder, or are foamed or specifically porous one layer being a fibrous or filamentary layer another layer also being fibrous or filamentary
The invention relates to an injection moulding process for producing components by injecting a thermoplastic melt into a mould, in which a sheet-like blank (14) comprising two or more woven or laid sheets of fibres that are bonded on one or both sides to a layer of random fibres and impregnated with a thermoplastic material is heated above the softening temperature of the thermoplastic, the porous blank expanded in this way is placed against one of the two inner walls (16, 17) of the mould, the mould is closed to compress the blank and opened again to the desired extent, and the thermoplastic melt is injected into the porous core. The invention also relates to components (24) in the form of planar, bent, curved or angled panels, which can be used in particular in the automobile sector.
B29C 70/48 - Shaping or impregnating by compression for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM]
In a method for producing a composite material, comprising A. a core layer (K) that contains at least 20% by volume air voids and is made of thermoplastic material reinforced with randomly oriented fibers, and B. reinforcement strips (V) made of continuous, parallel, unidirectional reinforcement fibers, which are embossed into the surface of the core layer either on one side or on both sides, the core layer is heated to temperatures above the softening range of the thermoplastic material. Thereafter, a plurality of individual fiber bundles, which were applied onto the surface of the core layer at a distance from each other, is pressed into said surface.
B29C 70/82 - Forcing wires, nets or the like partially or completely into the surface of an article, e.g. by cutting and pressing
B29C 70/88 - Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
12.
COMPOSITE SHEET BASED ON HIGH PRESSURE LAMINATE SHEETS (HPL SHEETS)
The invention relates to a composite sheet comprising top layers of high pressure laminate sheets A and a core layer B arranged therebetween. The core layer is formed from an air-pore-containing, fibre-reinforced thermoplastic and is adhesively bonded to the top layers.
B32B 5/18 - Layered products characterised by the non-homogeneity or physical structure of a layer characterised by features of a layer containing foamed or specifically porous material
E04C 2/22 - Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of wood, fibres, chips, vegetable stems, or the likeBuilding elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of plasticsBuilding elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials of foamed products of plastics reinforced
13.
METHOD FOR THE PRODUCTION OF MOLDED PARTS MADE OF FIBER-REINFORCED POLYPROPYLENE CONTAINING PORES
The invention relates to a method for the production of light-weight molded parts, wherein a heated pre-cut part made of fiber-reinforced polypropylene (6) containing pores is inserted into a two-part mold, and overlapping the edge thereof heated strips made of fiber-reinforced polypropylene (5) containing pores are inserted, pressed, and deformed in the process.
The invention relates to a method for producing a thermoformable composite material in which a mixed nonwoven of thermoplastic fibres and reinforcing fibres is hot-pressed under low pressure together with a hydrophobized mixed-fibre nonwoven of polyethylene terephthalate fibres and polypropylene fibres.
B29C 70/50 - Shaping or impregnating by compression for producing articles of indefinite length, e.g. prepregs, sheet moulding compounds [SMC] or cross moulding compounds [XMC]
B29L 31/30 - Vehicles, e.g. ships or aircraft, or body parts thereof
The invention relates to a flat semifinished product which has been reinforced with needled glass fiber mats and comprises, as a matrix, a mixture of polypropylene, a polyamide and a maleic anhydride-grafted polypropylene.
C08L 51/06 - Compositions of graft polymers in which the grafted component is obtained by reactions only involving carbon-to-carbon unsaturated bondsCompositions of derivatives of such polymers grafted on to homopolymers or copolymers of aliphatic hydrocarbons containing only one carbon-to-carbon double bond
C08L 77/00 - Compositions of polyamides obtained by reactions forming a carboxylic amide link in the main chainCompositions of derivatives of such polymers