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WO2000013892A1 - Construction en sandwich - Google Patents

Construction en sandwich Download PDF

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Publication number
WO2000013892A1
WO2000013892A1 PCT/SE1999/001523 SE9901523W WO0013892A1 WO 2000013892 A1 WO2000013892 A1 WO 2000013892A1 SE 9901523 W SE9901523 W SE 9901523W WO 0013892 A1 WO0013892 A1 WO 0013892A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
sandwich construction
metal layer
thermoplastic
composite layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/SE1999/001523
Other languages
English (en)
Inventor
Göran Langstedt
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Linlan Induction AB
Original Assignee
Linlan Induction AB
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from SE9802982A external-priority patent/SE9802982D0/xx
Application filed by Linlan Induction AB filed Critical Linlan Induction AB
Priority to AU60150/99A priority Critical patent/AU6015099A/en
Publication of WO2000013892A1 publication Critical patent/WO2000013892A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/088—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of non-plastics material or non-specified material, e.g. supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—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
    • B29C70/882—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 partly or totally electrically conductive, e.g. for EMI shielding
    • B29C70/885—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 partly or totally electrically conductive, e.g. for EMI shielding with incorporated metallic wires, nets, films or plates
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/04—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the partial melting of at least one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/10—Fibres of continuous length
    • B32B2305/18—Fabrics, textiles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/02—Temperature
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/04—Time
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/12—Pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2309/00—Parameters for the laminating or treatment process; Apparatus details
    • B32B2309/60—In a particular environment
    • B32B2309/62—Inert
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00—Metals, their alloys or their compounds
    • B32B2311/24—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2398/00—Unspecified macromolecular compounds
    • B32B2398/20—Thermoplastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2605/00—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B60—VEHICLES IN GENERAL
    • B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
    • B60R21/00—Arrangements or fittings on vehicles for protecting or preventing injuries to occupants or pedestrians in case of accidents or other traffic risks
    • B60R21/02—Occupant safety arrangements or fittings, e.g. crash pads
    • B60R21/16—Inflatable occupant restraints or confinements designed to inflate upon impact or impending impact, e.g. air bags
    • B60R21/23—Inflatable members
    • B60R21/235—Inflatable members characterised by their material
    • B60R2021/23504—Inflatable members characterised by their material characterised by material
    • B60R2021/23523—Composite

Definitions

  • the present invention relates to a sandwich construction as well as manufacture and use thereof.
  • Background Art It is generally known that body metal sheets for vehicles, such as automobiles, and casings and chassis for machinery, instruments and apparatus of different kinds are relatively heavy owing to dimensioning in respect of rigidity, strength in complex loads, safety in connection with, for instance, collisions and damping of oscillations and impacts. There is an increasing demand for a reduced weight of such constructions.
  • a problem in screening of electromagnetic radiation from electronic equipment is that electric sheets that are otherwise used in e.g. transformers must usually be applied to the casing or chassis or between sheets therein. There is thus a demand for simpler constructions, where the screening metal layer is integrated in such chassis or casings.
  • no technique is presently available that permits the manufacture of such constructions in a mould without reducing their strength and, thus, their safety.
  • US-A-5 164 141 (Bayer Aktiengesellschaft) refers to a process for the continuous production of laminated sheets, particularly flat fibre reinforced thermoplastic matrix composite laminates with a metal surface for electric shielding purposes.
  • EP-A2-0 743 174 (YKK Corporation) describes laminated plate material and loom harness frame manufactured therefrom. The loom produced has been designed for weight reduction and minimisation of inertia for the specific purpose of loom shafts. Summary of the Invention
  • An object of the present invention is to solve the above problems and satisfy the above defined demands. According to the present invention this object is achiev- ed by providing a sandwich construction which has the features defined in the accompanying claim 1, is light and strong and can replace body metal sheets for vehicles as well as casings and chassis for different machinery, instruments and apparatus, for instance those emitting electromagnetic radiation. Preferred embodiments are recited in the dependent claims. The invention also concerns methods for manufacturing this sandwich construction and use of the same in the above-mentioned fields. Brief Description of the Drawings Fig. 1 shows an embodiment of a sandwich construction according to the invention which is provided with only one metal layer.
  • Fig. 2 shows another embodiment of a sandwich construction according to the invention which contains a steel wool layer.
  • Fig. 3 shows the ratio of force to deflection for a composite panel based on the sandwich construction according to the present invention.
  • the invention relates to a sandwich construction which is characterised in that it comprises a fibre- and thermoplastic-containing composite layer, a first metal layer, and optionally a second metal layer, the composite layer comprising one or more fabric layers with reinforcing fibres arranged therein, and a thermoplastic distributed in the composite layer, and the composite layer being connected to the first and optionally second metal layers by melting and solidifying of the thermoplastic when heating and simultaneously com- pressing the layers.
  • the sandwich construction shown in Fig. 1 comprises a fibre- and thermoplastic-containing composite layer 1, which in turn comprises one or more fabric layers 4.
  • a plurality of fabric layers 4 can be oriented in different directions with a view to increasing the strength of the sandwich construction.
  • the fabric layers 4 can also be arranged in a varying manner in one and the same plane, for instance when different degrees of strength are desirable in different parts or directions of the sandwich construction.
  • the fabric layer 4 can originally be a pure fibrous tissue or originate from a material where a fibrous tissue or mat is preimpregnated with polymer material or where the polymer material is in the form of fibres or film or is mixed, interlaced, woven, braided, non-woven or knitted in the fibrous tissue, such as a prepreg.
  • ground-down fibrous fragments can be present in the composite layer 1.
  • Use is preferably made of fabrics of the Splitfilm Warpnits type, whereby in varying forming of the sandwich construction the fibres can, during compression, be draped over complex curved surfaces and stretched without losing their strength.
  • the fibre material can thus consist of any type of fibres which has satisfactory strength properties.
  • Use is preferably made of glass fibres, armid fibres or carbon fibres, but also hemp and other textile fibres, such as flax and sisal, are usable.
  • the fabric layer (s) 4 contain (s) arranged reinforcing fibres twisted into yarn structures.
  • the fibre diameter is about 5-25 ⁇ m for glass, armid and carbon fibres, and is normally about 1-50 ⁇ m for textile fibres.
  • Yarns made from such fibres normally have a diameter of about 0.1-1.0 mm. Further, each fibre has a low twist value of about 0.1-200 m" 1 , preferably 5-100 m "1 .
  • the yarns may be present in the composite layer 1 in a wave shaped configuration having a wave length of 2-100 mm. Yarns of different wave configurations, both as to amplitude and as to wave length, may be present in the composite layer 1. In one embodiment, the amplitude of the yarn wave length is close to the interface between the metal layer 2, and optionally 3, and the composite layer 1.
  • twist value as used herein is defined as the amount of turns of a fibre string around its own axis per length unit, expressed in m -1 .
  • the thermoplastic component in the composite layer 1 can be any suitable thermoplastic polymer, e.g. high- temperature plastics, such as polyimides, but preferably use is made of polypropylene, polyamides or polyesters. Examples of usable polyesters are PET and PBT. It may have been added as raw material to the composition in the form of polymer filaments extending adjacent to the fibre filaments in the layer of fabric layer 4.
  • the thermo- plastic component can also have been added in the form of recycled fibre polymer composite material or in the form of surface-treated material from recycled PET bottles.
  • a preferred material is the above-mentioned prepreg, i.e.
  • thermoplastic is molten in a controlled way such that it is only partially distributed in the composite layer 1.
  • the degree of distribution is defined as the penetration depth of the total thickness of the composite layer 1, starting from the interface between the metal layer 2 and the composite layer 1.
  • the penetration depth amounts to the total penetration depths, i.e. that seen from the interface between the composite layer 1 and the metal layer 2 and that seen from the interface between the composite layer 1 and the metal layer 3.
  • the penetration depth is about 30-80%, de- pending on the final use of the sandwich construction.
  • the penetration depth is not exactly the same throughout the composite layer. Instead, slight variations in penetration depth may occur depending on the fluctuations in the heat treatment conditions and in homogenity in the starting materials used. Therefore, the amounts of penetration depth indicated throughout the application are intended to be mean values.
  • the composite layer 1 there is a part of 20-70% that is not infiltrated by the thermoplastic, and this part essen- tially contains fabric material .
  • Such a composite layer 1 partially containing a thermoplastic has been found to be particularly strong, tough and energy absorbing. Further, with the non-penetrated part essentially containing fabric in the composite layer 1, undesired stiffness of the sandwich constructions is avoided. Also, deep drawing of such a construction is facilitated.
  • non-bound free fibre length One important parameter in this context is the "non- bound free fibre length" .
  • the thermoplastic is molten to a controlled penetration depth in the composite layer 1 during the production process, some parts of the yarns in the fabric are infiltrated by the thermoplastic, while other parts thereof remain non-infiltrated.
  • the yarn parts infiltrated are, of course, located closest to the interface between the composite layer 1 and the metal layer 2, and vice versa concerning the optional metal layer 3.
  • the parts of the wave-formed fibre yarns not infiltrated are defined as the "non-bound free fibre length” , and the remaining infiltrated parts are defined “bonded fibre lengths” .
  • the "non-bound free fibre length” is 0.1-20 mm, preferably 1-9 mm.
  • sandwich constructions in which the entire composite layer 1 is infiltrated with thermoplastic have reduced strength and energy absorbing capacity, but are nevertheless useful in certain applications.
  • the design and operation of the press tool to be used mean that the composite layer 1 can be made compact with no or just a few inclusions of air.
  • the thickness of the composite layer 1 is not critical, but depends on the intended use of the sandwich construction. However, the thickness should essentially exceed the thickness of the first metal layer 2.
  • the composite layer 1 can optionally also comprise one or more metal wool layers 5, e.g. steel wool or aluminium wool, and a second metal layer 3. If steel wool is used, it must be clean, i.e. it must not be of the lathery type intended for domestic use.
  • the steel wool which should preferably also be degreased and etched, or the other metal wool, can be supplied in a conventional manner in the form of a roll. The purpose of the presence of metal wool is on the one hand that it has great fractional toughness giving protection against penetration by external objects, e.g.
  • the first metal layer 2 on one side, preferably the upper side, of the composite layer 1 may consist of conventional vehicle sheet metal with satisfactory deep- drawing qualities.
  • the metal layer 2 is made of aluminium which besides can be pretreated to improve adhesion to the composite layer and to prevent oxidation and corrosion. Its thickness is about 0.05-0.5 mm.
  • the metal layer 2 gives the sandwich construction a metal surface and an impression of a compact metal construction. If e.g. car bodies are involved, it is for instance not possible to distinguish that the body material is not made of metal throughout . Further the metal layer 2 of the prepared sandwich construction can be painted just like a conventional car body, e.g.
  • a heat-resisting layer of primer e.g. paint
  • the surface of the first metal layer 2 that is to be bound to the composite layer 1 can optionally be pretreated to facilitate the binding between the two layers.
  • the second metal layer 3 which optionally is bound to the other side of the composite layer 1 is not necessary in all applications, but may be desirable in other applications of the sandwich construction, e.g. in car bodies.
  • a composite layer 1 may, as mentioned above, consist of one or more fabric layers 4 with fibrous tissues oriented in the same or different direction in the plane of the sandwich construction.
  • the thickness of the layer, the fibre diameter and extent of the selected fibre material are not critical, but may also vary according to the application of the sandwich construction.
  • a plurality of metal wool layers 5, e.g. steel wool layers may also be included in the composite layer 1, and the thickness and extent of these layers are not critical either, but may vary according to the application of the sandwich construction.
  • the sandwich construction consists of a plura- lity of different layers, it is understood that all the described layers are parallel or essentially parallel with each other.
  • the sandwich construction can practi- cally have any shape and extent whatever, provided that this can be achieved by means of the press tool or compression moulding die.
  • the cross-section of the construction should be essentially identical in re- spect of the thickness of the various layers even if it has been bent or deformed in some other manner during mould compression, e.g. by deep-drawing.
  • the sandwich construction according to the present invention is manufactured by first placing the components included therein in the desired order in a cold press tool or compression moulding die, which optionally may first have been coated with a release agent.
  • a cold press tool or compression moulding die which optionally may first have been coated with a release agent.
  • Any press tool which yields the conditions stated below can be used, but preferably use is made of a press tool as de- scribed in PCT Applications SE97/00600 (priority claimed from Swedish Patent Application No. 9600130-0) , applicant Linlan Induction AB, i.e. under the action of conductive heat and with the aid of vibration assistance from the heating frequency and its harmonics.
  • the press tool of SE97/00600 is said therein to be intended only for the manufacture of products wholly or partly consisting of plastic or a composite material.
  • a pressure of 0.5-50 kg/cm 2 is usable and is dependent on the surface state of the metal sheet, the type of polymers and the heating tem- perature.
  • the polymer melts is bonded to the fibres and distributed to a controlled, desired penetration depth in the composite layer 1.
  • the press tool die is cooled under pressure to about 50°C. In this fashion the polymer is cooled and solidi- fies, thereby achieving a strong bond between the thermoplastic of the composite layer 1 and the first and optionally the second metal layer 2, 3.
  • the die is then opened, and the prepared sandwich construction can be removed.
  • the total process time including cooling is below 5 min, preferably 0.5-5 min.
  • the actual heating step lasts from about 10 s to about 3 min, depending on the size of the press tool die and the supplied power.
  • the satisfactory strength properties such as excel- lent final strength in large deformations, that are achieved at the low pressure can be attributed to, for example, the composition of the starting textile, i.e. discrete weft yarns in a textile structure consisting of the matrix material, the yarns having a long twist value of 0.1-100 m _1 , preferably about 2 m -1 .
  • an about 0.2-mm-thick aluminium sheet is placed in the above described press tool die.
  • a 4-mm-thick composite layer 1 is applied, comprising a prepreg as defined above, i.e. a fabric with, for instance, preimpregnated or interlaced polypropylene.
  • the fibre twist value in the prepreg is about 10 m" 1 and the non-bonded free fibre length is 5-10 mm.
  • a steel wool layer 5 is applied, followed by a composite layer 1 identical with the one described above, and a second metal layer 3.
  • the material in the press tool die is then heated for a period of 30 s max to about 230°C at a pressure of about 20 kg/cm 2 during the compression of the aluminium sheets .
  • the total process time including the steps of placing the in- gredients in the compression moulding die and cooling, amounts to 5 min max and the penetration depth for the thermoplastic is 20% starting from the interface between the composite layer 1 and each of the metal layers 2,3, i.e. totally 40%.
  • the first and optionally the second metal layer 2, 3 can be premoulded by compression before the ingredients in the composite layer 1 are applied.
  • this metal layer or these metal layers then act as a mould with the necessary support and can be considered to replace the metal surface of the compression mould.
  • the ingredients in the composite layer 1, optionally one or more steel wool layers 5 and the already prepressed metal layer or layers are then compressed under the same conditions as just above, but at a pressure of about 1 kg/cm 2 to a sandwich construction according to the present invention.
  • the metal can also be recovered separately, as can also the composite part with fibres and polymer.
  • the manufacture of the sandwich construction occurs by continuous feeding of one or more metal layers from a roll and feeding of one or more fabric layers with thermoplastic from a roll to the compression moulding die.
  • the metal layer or layers fed can be painted in advance. Since the atmosphere inside the press tool die is deoxidised, the paint withstands the high temperature without being degraded.
  • the layers are cut off, whereupon moulding occurs and the process is then repeated.
  • the process cycle time is 0.5-5 min, preferably 1-3 min.
  • the end product may be cut off when exiting the press tool die.
  • two metal sheet layers and one glass fibre layer with thermoplastic in the form of a prepreg are supplied to the compression moulding die in such manner that the glass fibre layer is positioned between the two plastic layers.
  • the metal layer (s) may be premolded by compression and put into the press tool before the other components are fed from the rolls to the tool. It is to be understood that in all of the embodiments above comprising continuous feeding, the manufacture conditions and the features of the components to be included in the sandwich construction are the same as in the preferred non-continuous method described above.
  • a first metal layer 2 a fabric layer with thermoplastic, one or more metal wool layers 5 and a second metal layer 3 are stapled in this order to a layer aggregate and is placed in a first induction heated furnace (frequency: 6 kHz) .
  • the metal layers 2 and 3 have been premoulded to their final shape .
  • the induction heated furnace the metal layers 2 and 3 are heated to such a temperature that the thermoplastic in the layer aggregate melts enough for to adhere to the metal layers 2 and 3 , whereby the whole layer aggregate becomes an integral construction.
  • the layer aggregate heated in the first furnace is allowed to cool, followed by optional cutting of the whole layer aggregate into its final shape, if desired. Thereafter, the layer aggregate is placed into a second induction heated furnace, in which it is heated for melting of the thermoplastic in a controlled way to the penetration depth desired, dependent on the final use. In the molten state, the thermoplastic acts as a glidant between the metal layers and the fibres. Then, when the thermoplastic is still in a molten state, the layer aggregate is quickly transferred to a cold press tool, in which the compression to the final shape takes place.
  • This alternative is particularly advantageous when the aggregate formed during the first heating step is to be transported to another geographic location for the final heating and compression treatment .
  • the layer aggregate formed after the first heating step is transferred directly to the cold press tool, i.e. without any second heating step.
  • the heating conditions in the induction heated furnace are more stringent in a view to obtaining the exact penetration depth desired.
  • the metal layers 2 and 3 are made of low carbon mild steel or aluminium having a thickness of 0.2 mm, the fibres are non-woven polypropylene and surface-treated PET from bottles, and the metal wool is steel wool.
  • the tempera- ture in the first furnace for inductive heating is about 220°C, the heating temperature is at most 10 s and the pressure is about 1 kg/cm 2 .
  • the layer aggregate is allowed to cool to less than 50°C during a period of less than 20 s.
  • the conditions during the second heating step are essentially the same as during the first heating step.
  • the sandwich construction according to the present invention can, as mentioned above, be used as vehicle body, preferably for passenger automobiles, but also for lorries, busses and trains. It can also be used in air freight containers and construction components in aircraft, such as panels, and in passenger automobiles as side airbags and frames in car seats and children's safety seats. A further application is wind deflectors for trucks and other vehicles for reducing the air resistance, but also casings or chassis for various machinery, instruments and apparatus, e.g. apparatus for domestic electronics. Further applications of the sandwich construction are in safety doors and cabinets, furniture and kitchen fittings. Moreover, the sandwich construction can replace packings in plate heat exchangers where the composite constitutes the packing. This results in a heat exchanger which need not be pressed by applying a high pressure for the packings not to leak, i.e. a type of welded heat exchanger with no welding seam.
  • a sandwich construction in which an electric sheet in the form of a sheet having a thickness of at least 0.1 mm has replaced the first layer of metal sheet 2, can be used.
  • the sandwich construction according to the present invention can also be used in casings or chassis for machinery, instru- ments and apparatus protecting against external electromagnetic radiation.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Composite Materials (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne une construction en sandwich à couche composite de fibres et de matériau thermoplastique (1), avec une première couche métallique (2), et éventuellement une seconde couche métallique (3). La couche composite (1) renferme une ou plusieurs couches de tissu (4) qui comportent des fibres de renfort et un matériau thermoplastique. Les fibres présentent un couple de torsion d'environ 0,1 à 100 m-1 et une longueur libre de fibre non liée allant de 0,1 à 20 millimètres. Le matériau thermoplastique est partiellement distribué dans la couche composite (1) jusqu'à une profondeur de pénétration d'environ 30 à 80 % de l'épaisseur totale de la couche composite (1), en partant de l'interface entre la première couche métallique (2) et la couche composite (1) et éventuellement en partant de l'interface entre la seconde couche métallique (3) et la couche composite (1).
PCT/SE1999/001523 1998-09-03 1999-09-03 Construction en sandwich Ceased WO2000013892A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU60150/99A AU6015099A (en) 1998-09-03 1999-09-03 Sandwich construction

Applications Claiming Priority (6)

Application Number Priority Date Filing Date Title
US9928498P 1998-09-03 1998-09-03
SE9802982A SE9802982D0 (sv) 1998-09-03 1998-09-03 Sandwichkonstruktion
US60/099,284 1998-09-03
SE9802982-0 1998-09-03
US12856599P 1999-04-09 1999-04-09
US60/128,565 1999-04-09

Publications (1)

Publication Number Publication Date
WO2000013892A1 true WO2000013892A1 (fr) 2000-03-16

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/SE1999/001523 Ceased WO2000013892A1 (fr) 1998-09-03 1999-09-03 Construction en sandwich

Country Status (2)

Country Link
AU (1) AU6015099A (fr)
WO (1) WO2000013892A1 (fr)

Cited By (18)

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WO2003035563A1 (fr) * 2001-10-26 2003-05-01 Langendorf Textil Gmbh & Co. Kg Structure textile plane
WO2004069586A1 (fr) * 2003-02-06 2004-08-19 Autoliv Development Ab Coussin gonflable pour dispositif de retenue d'occupant, procede d'installation du coussin gonflable, et dispositif de retenue de la portion de taille d'occupant
WO2010021899A1 (fr) * 2008-08-18 2010-02-25 Productive Research LLC. Composites légers aptes à la mise en forme
US20130272780A1 (en) * 2010-11-30 2013-10-17 Teijin Limited Joint Member and Method for Producing the Same, and Method for Producing Metal Composite Molded Product
US20140178633A1 (en) * 2011-03-24 2014-06-26 Thyssenkrupp Steel Europe Ag Composite Material and Structural Components of a Motor Vehicle
US8796580B2 (en) 2009-12-28 2014-08-05 Productive Research Processes for welding composite materials and articles therefrom
US20150030864A1 (en) * 2012-04-09 2015-01-29 Teijin Limited Method for Manufacturing Joint Member and Joint Member
US20150064409A1 (en) * 2012-03-29 2015-03-05 Teijin Limited Method for Manufacturing Joint Member and Joint Member
US9005768B2 (en) 2011-02-21 2015-04-14 Productive Research Composite materials including regions differing in properties and methods
WO2015075684A1 (fr) * 2013-11-22 2015-05-28 全耐塑料公司 Demi-produit préimprégné, sa préforme tridimensionnelle et son élément moule recouvert de plastic
US9115264B2 (en) 2010-02-15 2015-08-25 Productive Research Llc Delamination resistant, weldable and formable light weight composites
US9233526B2 (en) 2012-08-03 2016-01-12 Productive Research Llc Composites having improved interlayer adhesion and methods thereof
WO2016087127A1 (fr) * 2014-12-01 2016-06-09 Thyssenkrupp Steel Europe Ag Matériau composite fibreux, procédé de fabrication d'un élément composite et utilisation dudit matériau composite fibreux
CN106273897A (zh) * 2016-08-08 2017-01-04 珠海新代复合材料有限公司 一种各向异性聚丙烯板‑金属复合材料及其制备方法
EP3101058A3 (fr) * 2015-05-14 2017-03-15 Johns Manville Préimprégnés thermoplastiques souples
CN110863294A (zh) * 2018-08-28 2020-03-06 米勒纺织品有限公司 间隔针织物和该间隔针织物的应用
US11225065B2 (en) 2019-08-27 2022-01-18 Joel Martz System and method for producing a heat-sealable composite liquid impervious, moisture-eliminating membrane with a metallic antimicrobial surface treatment
US11338552B2 (en) 2019-02-15 2022-05-24 Productive Research Llc Composite materials, vehicle applications and methods thereof

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WO2003035563A1 (fr) * 2001-10-26 2003-05-01 Langendorf Textil Gmbh & Co. Kg Structure textile plane
WO2004069586A1 (fr) * 2003-02-06 2004-08-19 Autoliv Development Ab Coussin gonflable pour dispositif de retenue d'occupant, procede d'installation du coussin gonflable, et dispositif de retenue de la portion de taille d'occupant
CN100450818C (zh) * 2003-02-06 2009-01-14 奥托利夫发展公司 乘客约束装置用充气气囊、其安装结构、及乘客腰部约束装置
KR100894233B1 (ko) * 2003-02-06 2009-04-20 오토리브 디벨로프먼트 에이비 탑승원 구속 장치용 인플레이터 백, 그 설치 구조 및탑승원 요부 구속 장치
US9434134B2 (en) 2008-08-18 2016-09-06 Productive Research Llc Formable light weight composites
WO2010021899A1 (fr) * 2008-08-18 2010-02-25 Productive Research LLC. Composites légers aptes à la mise en forme
US7927708B2 (en) 2008-08-18 2011-04-19 Productive Research Llc Formable light weight composites
US8540842B2 (en) 2008-08-18 2013-09-24 Productive Research Llc Formable light weight composites
US9889634B2 (en) 2008-08-18 2018-02-13 Productive Research Llc Formable light weight composites
US8796580B2 (en) 2009-12-28 2014-08-05 Productive Research Processes for welding composite materials and articles therefrom
US11331880B2 (en) 2010-02-15 2022-05-17 Productive Research Llc Delamination resistant, weldable and formable light weight composites
US11084253B2 (en) 2010-02-15 2021-08-10 Productive Research Llc Light weight composite material systems, polymeric materials, and methods
US10710338B2 (en) 2010-02-15 2020-07-14 Productive Research Llc Delamination resistant, weldable and formable light weight composites
US9115264B2 (en) 2010-02-15 2015-08-25 Productive Research Llc Delamination resistant, weldable and formable light weight composites
US10457019B2 (en) 2010-02-15 2019-10-29 Productive Research Llc Light weight composite material systems, polymeric materials, and methods
US9981451B2 (en) 2010-02-15 2018-05-29 Productive Research Llc Delamination resistant, weldable and formable light weight composites
US9415568B2 (en) 2010-02-15 2016-08-16 Productive Research Llc Formable light weight composite material systems and methods
US9849651B2 (en) 2010-02-15 2017-12-26 Productive Research Llc Formable light weight composite material systems and methods
US20130272780A1 (en) * 2010-11-30 2013-10-17 Teijin Limited Joint Member and Method for Producing the Same, and Method for Producing Metal Composite Molded Product
US9005768B2 (en) 2011-02-21 2015-04-14 Productive Research Composite materials including regions differing in properties and methods
US9962909B2 (en) 2011-02-21 2018-05-08 Productive Research Llc Composite materials including regions differing properties, and methods
US20140178633A1 (en) * 2011-03-24 2014-06-26 Thyssenkrupp Steel Europe Ag Composite Material and Structural Components of a Motor Vehicle
US9527230B2 (en) * 2012-03-29 2016-12-27 Teijin Limited Method for manufacturing joint member and joint member
US20150064409A1 (en) * 2012-03-29 2015-03-05 Teijin Limited Method for Manufacturing Joint Member and Joint Member
US20150030864A1 (en) * 2012-04-09 2015-01-29 Teijin Limited Method for Manufacturing Joint Member and Joint Member
US9233526B2 (en) 2012-08-03 2016-01-12 Productive Research Llc Composites having improved interlayer adhesion and methods thereof
US10427386B2 (en) 2013-11-22 2019-10-01 Compagnie Plastic Omnium Semi-finished product manufactured from prepreg, three-dimensional preformed body and overmolded part
WO2015075684A1 (fr) * 2013-11-22 2015-05-28 全耐塑料公司 Demi-produit préimprégné, sa préforme tridimensionnelle et son élément moule recouvert de plastic
WO2016087127A1 (fr) * 2014-12-01 2016-06-09 Thyssenkrupp Steel Europe Ag Matériau composite fibreux, procédé de fabrication d'un élément composite et utilisation dudit matériau composite fibreux
EP3101058A3 (fr) * 2015-05-14 2017-03-15 Johns Manville Préimprégnés thermoplastiques souples
CN106273897A (zh) * 2016-08-08 2017-01-04 珠海新代复合材料有限公司 一种各向异性聚丙烯板‑金属复合材料及其制备方法
CN110863294A (zh) * 2018-08-28 2020-03-06 米勒纺织品有限公司 间隔针织物和该间隔针织物的应用
US11338552B2 (en) 2019-02-15 2022-05-24 Productive Research Llc Composite materials, vehicle applications and methods thereof
US11225065B2 (en) 2019-08-27 2022-01-18 Joel Martz System and method for producing a heat-sealable composite liquid impervious, moisture-eliminating membrane with a metallic antimicrobial surface treatment

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