Plastic and nonmetallic article shaping or treating: processes – Mechanical shaping or molding to form or reform shaped article – To produce composite – plural part or multilayered article
Patent
1996-12-20
2000-02-29
Silbaugh, Jan H.
Plastic and nonmetallic article shaping or treating: processes
Mechanical shaping or molding to form or reform shaped article
To produce composite, plural part or multilayered article
264231, 264322, 264324, 264263, 156166, 156296, 156242, 156245, 425521, 425406, 425DIG37, 425DIG38, 425DIG48, B28B 300
Patent
active
060305681
DESCRIPTION:
BRIEF SUMMARY
DESCRIPTION
The present invention relates to a method for producing a fibre reinforced three-dimensional product of a plastic material by using a mould in which the product is formed, wherein a plane laminate of crossing fibre arrangements is formed containing long fibres which are uniformly oriented and which are mixed with a plastic matrix.
Methods of the type mentioned in the introduction are known wherein, during application of a three-dimensional shape, the formed plane laminate is not secured in the mould in which it is deposited. If short or cut fibres are used for reinforcement of the plastic material, the material will normally not be secured. Owing to this, it is not possible to control the orientation and distribution of the fibres when the product is given a three-dimensional shape. Thus, the finished and three-dimensional product will not always have well-defined material properties throughout its extent.
A method is known from U.S. Pat. No. 5,312,579 for the manufacture of a laminate. According to this method prepreg plies each consists of unidirectional fibres. It is described that moulding stops are used and that the plies are arranged within the mould. It is the object to ensure that no air is entrapped in the laminate. There is no mentioning of any method of securing the prepreg plies in relation to any of the mould parts. Accordingly, if the product should be given a three-dimensional shape then there would be no control of the orientation of the fibres as explained above.
Methods are also known, e.g. from EP-A-0,202,041, wherein the plane laminate is secured partially in all directions so that a displacement of the deposited material is possible when it is given a three-dimensional shape.
Such potential for displacement in the material means that the orientation of the reinforcement fibres in the end product does not correspond to the orientation that the reinforcement fibres are given in the deposited plane laminate before a three-dimensional shape is applied to it. Thus, in the three-dimensional end product there will be larger distance between individual reinforcement fibres when an object is given a three-dimensional shape that is different from a plane deposit. Thus, at the same thickness of material throughout the surface of the object, the percentage content of reinforcement fibres will fall and become less the larger the distance from a plane original laminate. As a result of this lower content of reinforcement fibres, there will appear falling strength in such parts of the finished product.
It is noted that the production of a three-dimensional product may take place by depositing a number of layers on a three-dimensional shape, such as described e.g. in U.S. Pat. No. 4,404,156 and U.S. Pat. No. 5,312,579. However, a method for a mass production industry would preferably use the method where a plane laminate is formed initially which is subsequently given its three-dimensional shape by pressing/deep pressing the previously formed laminate.
The present invention is primarily intended for this method, but the method may also be used in the production of plane products or substantially plane products in which it is possible to provide the long fibres with a predefined orientation. In this manner, the finished product may be given various mechanical properties such as different strengths in different orientations.
It is the object of the present invention to remedy the disadvantages of the known methods by disclosing a method and a mould wherein long unidirectional fibres are used which will be evenly distributed even in areas of the finished product which has been subjected to the largest three-dimensional displacement in relation to the plane deposited laminate.
This is achieved according to the present invention by a method which is characterized in that the laminate is deposited loosely on a carrier net with first ends of the long fibres projecting out from the laminate, that the deposited product is heated, that only said first ends of the long fibres are securing secured by
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Gray Robin S.
Silbaugh Jan H.
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