Compression molding method of multi-layer and multi-functional thermoplastic composite material structure

Abstract

A method of manufacturing a multi-layer and multi-functional thermoplastic composite structure includes supplying a plurality of reinforcing layers including continuous reinforcing fibers and a thermoplastic resin to an intermittent press; and supplying the at least one functional layer to the intermittent press adjacent to the plurality of reinforcement layers. The at least one functional layer is selected from an electromagnetic shielding layer and a thermal runaway protection layer. The method includes heating and pressing a plurality of reinforcement layers and at least one functional layer to form a composite laminate.

Description

Technical Field

[0001] The present disclosure relates to methods for making multi-layer and multifunctional thermoplastic composite structures. Background Art

[0002] The information provided in this section is intended to generally introduce the background of the present disclosure. To the extent that work currently named as inventors is described in this section, and aspects of the specification that may not have been otherwise identified as prior art at the time of filing, are not admitted, either explicitly or implicitly, as prior art to the present disclosure.

[0003] The present disclosure relates to methods for making multilayer and multifunctional thermoplastic composite structures.

[0004] An electric vehicle (EV), such as a battery electric vehicle (BEV), a hybrid vehicle, and / or a fuel cell vehicle, includes one or more motors and a battery system including one or more battery cells, modules, and / or battery packs. A battery control module is used to control the charging and / or discharging of the battery system during charging and / or driving. EV manufacturers are pursuing increased power density to increase the range of EVs.

[0005] Battery modules and / or battery packs are arranged in a housing that is typically made of metal such as steel or aluminum. In addition to providing structural support functions, the housing may also need to perform other functions, such as thermal insulation, flame retardancy and / or electromagnetic shielding. When structural components are made of aluminum or steel, the structural components may be relatively heavy. Summary of the invention

[0006] A method for manufacturing a multilayer and multifunctional thermoplastic composite laminate, comprising: supplying a plurality of reinforcing layers comprising continuous reinforcing fibers and a thermoplastic resin to an intermittent press; and supplying at least one functional layer adjacent to the plurality of reinforcing layers to the intermittent press. The at least one functional layer is selected from an electromagnetic shielding layer and a thermal runaway protection layer. The method comprises heating and pressing a plurality of reinforcing layers and at least one functional layer to form a composite laminate.

[0007] In other features, the at least one functional layer includes a first functional layer disposed on one side of the plurality of reinforcement layers; and a second functional layer disposed on an opposite side of the plurality of reinforcement layers.

[0008] In other features, the method includes cooling the composite laminate using an intermittent press after pressing and heating. The method includes arranging the composite laminate in a compression molding tool; arranging a discontinuous fiber reinforcement material in the compression molding tool; and consolidating the discontinuous fiber reinforcement material with the composite laminate to form a multilayer and multifunctional thermoplastic composite structure.

[0009] In other features, the discontinuous fiber reinforcement material includes chopped unidirectional tapes, the chopped unidirectional tapes including reinforcing fibers selected from the group consisting of carbon fibers, glass fibers, basalt fibers, aramid fibers, and combinations thereof. The method includes coating a multilayer and multifunctional thermoplastic composite structure. The method includes curing the coating.

[0010] In other features, the compression molding tool includes a heater. The heater includes an induction heater. The method includes arranging a composite laminate on a support member, the support member including a frame defining an interior cavity and a mesh material extending over the interior cavity between edges of the frame. The method includes placing the composite laminate and the support member in an oven and heating the composite laminate and the support member for a predetermined period of time.

[0011] In other features, the method includes arranging the composite laminate and the support member in a compression molding tool and pressing the composite laminate to form a multilayer and multifunctional thermoplastic composite structure. The continuous reinforcing fiber is selected from carbon fiber, glass fiber, basalt fiber, aramid fiber and a combination thereof. The continuous reinforcing fiber is pre-impregnated with a thermoplastic polymer matrix selected from polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS), polyetherimide (PEI), low melting point PEEK (LMPEEK), polyaryletherketone (PAEK) and a combination thereof.

[0012] A method for manufacturing a multi-layer and multifunctional thermoplastic composite structure, comprising arranging at least one functional layer in a cavity of a compression molding tool, wherein the at least one functional layer is selected from an electromagnetic shielding layer and a thermal runaway protection layer. The method comprises arranging a discontinuous fiber reinforcement material in the cavity of the compression molding tool; and heating and pressing the at least one functional layer and the discontinuous fiber reinforcement material to form a multi-layer and multifunctional thermoplastic composite structure.

[0013] In other features, the compression molding tool includes at least one of an induction heater and a cooling channel configured to contain a coolant. The method includes coating a multi-layer and multifunctional thermoplastic composite structure; and curing the coating.

[0014] In other features, the discontinuous fiber reinforcement material comprises a chopped unidirectional tape comprising reinforcing fibers selected from the group consisting of carbon fibers, glass fibers, basalt fibers, aramid fibers, and combinations thereof. The discontinuous fiber reinforcement material is pre-impregnated with a thermoplastic polymer matrix selected from the group consisting of polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS), polyetherimide (PEI), low melting point PEEK (LMPEEK), polyaryletherketone (PAEK), and combinations thereof.

[0015] The present invention discloses the following scheme:

[0016] Scheme 1. A method for manufacturing a multilayer and multifunctional thermoplastic composite laminate, comprising:

[0017] supplying a plurality of reinforcement layers comprising reinforcing fibers and a thermoplastic resin to a batch press;

[0018] supplying at least one functional layer adjacent to the plurality of reinforcing layers to the batch press,

[0019] wherein the at least one functional layer is selected from an electromagnetic shielding layer and a thermal runaway protection layer; and

[0020] The plurality of reinforcement layers and the at least one functional layer are heated and pressed to form a composite laminate.

[0021] Option 2. The method according to Option 1, wherein the at least one functional layer comprises:

[0022] A first functional layer disposed on one side of the plurality of reinforcement layers; and

[0023] A second functional layer is disposed on an opposite side of the plurality of reinforcement layers.

[0024] Option 3. The method according to Option 1 further includes cooling the composite laminate using the intermittent press after pressing and heating.

[0025] Solution 4. The method according to Solution 1 further includes:

[0026] placing the composite laminate in a compression molding tool;

[0027] placing a discontinuous fiber reinforcement material in the compression molding tool; and

[0028] consolidating the discontinuous fiber reinforcement material with the composite laminate to form a multilayer and multifunctional thermoplastic composite structure,

[0029] wherein the discontinuous fiber reinforcement material flows into the reinforcement features of the mold cavity.

[0030] Option 5. The method according to Option 4, wherein the discontinuous fiber reinforcement material comprises chopped unidirectional tapes, and the chopped unidirectional tapes comprise reinforcing fibers selected from the group consisting of carbon fibers, glass fibers, basalt fibers, aramid fibers, and combinations thereof.

[0031] Option 6. The method according to Option 4 also includes coating the multilayer and multifunctional thermoplastic composite structure.

[0032] Option 7. The method according to Option 6 also includes curing the coating.

[0033] Option 8. A method according to Option 4, wherein the compression molding tool includes a heater.

[0034] Option 9. A method according to Option 8, wherein the heater comprises an induction heater.

[0035] Option 10. The method according to Option 1 further includes arranging the composite laminate on a support member, the support member including a frame defining an inner cavity and a mesh material extending above the inner cavity between edges of the frame.

[0036] Option 11. The method according to Option 10 further includes placing the composite laminate and the support member in an oven and heating the composite laminate and the support member for a predetermined period of time.

[0037] Option 12. The method according to Option 11 also includes arranging the composite laminate and the supporting member in a compression molding tool and pressing the composite laminate to form the multi-layer and multifunctional thermoplastic composite structure.

[0038] Option 13. The method according to Option 1, wherein the reinforcing fiber is selected from the group consisting of carbon fiber, glass fiber, basalt fiber, aromatic polyamide fiber and combinations thereof.

[0039] Option 14. A method according to Option 13, wherein the reinforcing fibers are pre-impregnated with a thermoplastic polymer matrix selected from polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS), polyetherimide (PEI), low melting point PEEK (LMPEEK), polyaryletherketone (PAEK) and combinations thereof.

[0040] Scheme 15. A method for manufacturing a multilayer and multifunctional thermoplastic composite structure, comprising:

[0041] Arranging at least one functional layer in a cavity of a compression molding tool,

[0042] wherein the at least one functional layer is selected from an electromagnetic shielding layer and a thermal runaway protection layer;

[0043] placing a discontinuous fiber reinforcement material in a cavity of the compression molding tool; and

[0044] The at least one functional layer and the discontinuous fiber reinforcement are heated and pressed to form a multi-layered and multifunctional thermoplastic composite structure.

[0045] Embodiment 16. The method according to embodiment 15, wherein the compression molding tool includes at least one of an induction heater and a cooling channel configured to contain a coolant.

[0046] Solution 17. The method according to Solution 15 further includes:

[0047] coating said multilayer and multifunctional thermoplastic composite structure; and

[0048] The coating is allowed to cure.

[0049] Embodiment 18. The method according to embodiment 15, wherein the discontinuous fiber reinforcement material comprises chopped unidirectional tapes, wherein the chopped unidirectional tapes comprise reinforcing fibers selected from the group consisting of carbon fibers, glass fibers, basalt fibers, aramid fibers, and combinations thereof.

[0050] Option 19. A method according to Option 14, wherein the discontinuous fiber reinforcement material is pre-impregnated with a thermoplastic polymer matrix selected from polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS), polyetherimide (PEI), low melting point PEEK (LMPEEK), polyaryletherketone (PAEK) and combinations thereof.

[0051] Further areas of applicability of the present disclosure will become apparent from the detailed description, claims and drawings.The detailed description and specific examples are intended to be illustrative only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] The present disclosure will be more fully understood through the detailed description and accompanying drawings, in which:

[0053] Figure 1 is a side cross-sectional view of an example of a battery cell;

[0054] Figure 2 is a side cross-sectional view of an example of a battery pack according to the present disclosure including a plurality of battery cells arranged in a housing made of a multi-layer and multifunctional thermoplastic composite structure;

[0055] FIG. 3A to FIG. 3C An example of a method of making a multilayer and multifunctional thermoplastic composite structure according to the present disclosure is illustrated;

[0056] Figures 4 to 5D Another example of a method of manufacturing a multilayer and multifunctional thermoplastic composite structure according to the present disclosure is illustrated;

[0057] Fig. 6A and Figure 6B illustrates another example of a method of manufacturing a multilayer and multifunctional thermoplastic composite structure according to the present disclosure; and

[0058] 7A to 7D Another example of a method for manufacturing a multi-layer and multifunctional thermoplastic composite structure according to the present disclosure is illustrated.

[0059] Among the drawings, reference numerals may be repeated to identify similar and / or identical elements. DETAILED DESCRIPTION

[0060] Although the methods for making multi-layer and multifunctional thermoplastic composite structures according to the present disclosure are described below in the context of a housing for a battery pack and / or an electric machine, the housing may be used in other applications.

[0061] The present disclosure relates to methods for compression molding multi-layer and multifunctional thermoplastic composite structures. The methods can be used to produce high-strength and / or high-stiffness thermoplastic composite structures that have functions such as thermal runaway propagation (TRP) protection, electromagnetic interference (EMI) shielding, and / or protection of vehicles and / or other applications from exposure to the environment. By way of example only, multi-layer and multifunctional thermoplastic composite structures can be used as housings for battery packs and motors, among other components.

[0062] Reference now Figure 1 and Figure 2 , the battery cell 10 includes C cathode electrodes 20-1, 20-2, ... and 20-C, where C is an integer greater than 1. The C cathode electrodes 20 include a cathode active material layer 24 arranged on one side or both sides of a cathode current collector 26. The battery cell 10 includes A anode electrodes 40-1, 40-2, ... and 40-A, where A is an integer greater than 1. The A anode electrodes 40 include an anode active material layer 42 arranged on one side or both sides of an anode current collector 46.

[0063] C cathode electrodes 20, A anode electrodes 40, and S separators 32 are arranged in a predetermined order in the housing 50, where S is an integer greater than 1. For example, S separators 32 are arranged between C cathode electrodes 20 and A anode electrodes 40. External tabs 28 and 48 extend from the current collector to allow the current collector to be connected to the terminal (not shown) of the battery cell. External tabs 28 and 48 may be arranged on the same side, opposite sides, and / or different sides of the current collector.

[0064] exist Figure 2 In the embodiment, the battery pack 58 is arranged in the housing 60 and includes M battery modules 56-1, 56-2, ... and 56-M, each battery module includes B battery cells 10 (e.g., battery cells 10-1, 10-2, ... and 10-B), where B and M are integers greater than 1. The housing 60 includes a cover 62 and a body 64 (or tray). In some examples, the multilayer and multifunctional thermoplastic composite structure further described below is used to manufacture the cover 62 and / or the body 64, the housing for the motor and / or other vehicle or non-vehicle components.

[0065] Reference now FIG. 3A to FIG. 3C , showing a method for manufacturing multilayer and multifunctional thermoplastic composite structures. Figure 3A In FIG. 1 , electromagnetic shielding material 120 (e.g., copper wire mesh or other material) is disposed in cavity 112 of lower mold portion 110. Figure 3B In the embodiment, discontinuous fiber reinforcement material 124 (eg, chopped unidirectional tape) is unidirectionally arranged or randomly dispersed on the electromagnetic shielding material in the cavity 112 of the lower mold portion 110. Figure 3C In the embodiment, a fire resistant material 128 is disposed on the discontinuous fiber reinforcement material 124 .

[0066] An upper mold portion (example shown below) including a plug (shown) is lowered onto the lower mold portion 110, and a thermoplastic resin is optionally supplied into the mold. In other examples, the discontinuous fiber reinforcement is pre-impregnated with a thermoplastic resin (and the resin is optionally supplied). Heat and pressure are applied to form a multilayer, multifunctional thermoplastic composite structure, such as a shell. In some examples, the compression pressure is less than 800 psi. In some examples, the compression molding process temperature is less than 750 ° F. In some examples, the electromagnetic shielding material 120 and / or the flame retardant material 128 are treated with plasma or flame surface treatment to enhance adhesion to the thermoplastic core.

[0067] In some examples, the discontinuous fiber reinforcement material is intended to flow into a reinforcing feature of the mold cavity, such as a stiffener, rib, channel, etc. This feature enables the pre-consolidated laminate to be used in structural applications (e.g., floors, walls), and the discontinuous fiber reinforcement material can flow into the reinforcing feature, such as a stiffener, rib, channel, rib, etc.

[0068] Reference now Figures 4 to 5D , shows another example of a method for manufacturing a multilayer and multifunctional thermoplastic composite structure. Figure 4In the embodiment of the present invention, the reinforcing fiber layer 211 is supplied to the intermittent press 230 by one or more rollers 210-1, 210-2, ... and 210-R, wherein R is an integer. In other examples, the reinforcing fiber layer 211 comprises a unidirectional fiber reinforced polymer tape layered with a quasi-isotropic structure, wherein the ply (ply) is placed in different directions (e.g., 0 degree / 90 degree / + / -45 degree). The core (core) can also be composed of discontinuous fiber reinforced nonwoven mats, which can be a single ply or stacked and consolidated into multiple plies. The core can also be composed of oriented long fiber melt.

[0069] A functional layer 213-1 is optionally supplied by a roller 212-1 on one side of a stack of layers 217 including reinforcing fiber layers 211. A functional layer 213-2 is optionally supplied by a roller 212-2 on the opposite side of the stack of reinforcing fiber layers 211.

[0070] The release layers 215-1 and 215-2 are optionally supplied to one or both outer sides of the layer stack 217 by rollers 214-1 and 214-2. The layer stack 217 is supplied to an intermittent press 230, where heating, pressing and / or cooling are performed. The material supply outputs a consolidated laminate 240. In some examples, the consolidated laminate 240 is optionally cut into one or more predetermined lengths. The release layer 215 can be removed from the consolidated laminate 240 before subsequent processing (e.g., compression molding described further below).

[0071] refer to FIG. 5A to FIG. 5D , shows another exemplary method of manufacturing a multilayer and multifunctional thermoplastic composite structure using a consolidated laminate. Figure 5A and Figure 5B In the embodiment, a consolidated laminate 240 and a discontinuous fiber reinforcement material 320 are supplied. Figure 5C and Figure 5D In the embodiment of the present invention, the consolidated laminate 240 and the discontinuous fiber reinforcement material 320 are arranged in the cavity 336 of the lower mold part 332. The upper mold part 338 including the plug 339 is lowered into the lower mold part 332, and heat and pressure are applied to stamp and form the multi-layer, multifunctional thermoplastic composite material 340.

[0072] Reference now Fig. 6A and Figure 6B , another example of a method for manufacturing a multi-layer, multifunctional thermoplastic composite material is shown. The upper mold portion 410 includes a plug 412, and the lower mold portion 420 includes a cavity 424 for accommodating the plug 412. A functional layer 426 (e.g., an EMI shielding layer and / or a TRP layer) is arranged in the cavity 424 together with a discontinuous fiber reinforcement material 428.

[0073] After placing the functional layer 426 and the discontinuous fiber reinforcement material 428, the upper mold portion 410 is pressed into the lower mold portion 420 to apply pressure and / or heat to produce a multilayer and multifunctional thermoplastic composite structure 450. In some examples, the upper mold portion 410 and / or the lower mold portion 420 include a heater 444 and / or a cooling channel 440 through which a coolant flows. In some examples, cooling is performed after applying heat and / or pressure. In some examples, the heater 444 includes a resistive heater or an induction heater.

[0074] After consolidation, the thermoplastic structural core material is optionally coated with one or more functional layers and cured. In some instances, spray coating, dip coating, and / or flow coating are performed. In some instances, curing is performed using heat or UV light. In other instances, curing occurs due to a chemical reaction between reactants in the coating material.

[0075] For example, the fire retardant layer includes a protective coating applied to the composite material structure. In some instances, the protective coating is applied in liquid form using spraying, dipping, flow coating and / or other suitable coating methods. In some instances, the coating comprises a flame retardant compound, an expansion material, a hydrated material and ceramics, and adhesives, solvents and other additives used in the coating. In some instances, when reactants are combined, the protective coating is cured using heat, UV exposure, moisture and / or a chemical reaction at room temperature (or another temperature).

[0076] In some examples, the EMI shielding layer comprises a coating applied to the composite structure in liquid form as described above and optionally cured. In some examples, the EMI shielding layer comprises a coating that includes conductive particles (e.g., copper, aluminum, silver, nickel, gold, tin, or graphene). In other examples, the shielding layer is applied using a metal plating process.

[0077] In some examples, discontinuous reinforcing fibers are flowed in a compression molding tool. In some examples, a discontinuous carbon fiber charge is placed on top of at least one functional layer, and the discontinuous reinforcing fiber charge is flowed within the mold cavity. In some examples, the compression molding tool is capable of rapid thermal cycling using both heating and cooling.

[0078] Reference now 7A to 7D , shows another example of a method for manufacturing a multilayer and multifunctional thermoplastic composite structure. Fig. 7A and Figure 7BIn the embodiment of the present invention, a consolidation laminate 512 (or an optional functional layer and discontinuous fibers that have not yet been consolidated) is arranged on a support member 520, which includes a frame 524 that defines an inner cavity and a mesh material 528 that extends between the edges of the frame 524 to cover the inner cavity. The consolidation laminate 512 includes one or more functional layers and discontinuous fibers as described above. In some instances, the mesh material 528 is made of aromatic polyamide fibers such as polyparaphenylene terephthalamide. In some instances, the frame 524 is made of metal, ceramic and / or other structural and temperature-resistant materials. In some instances, the mesh material 528 is tightened between the edges of the frame 524. In other instances, the edges of the mesh material 528 are firmly held by the frame 524, and the mesh material 528 has enough slack to allow it to be overlaid on the contour of the tool / mold.

[0079] exist Figure 7C In the embodiment, the support member 520 and the consolidated laminate 512 are preheated in a heater 530 for a predetermined heating period of time before being stamped and formed in a compression molding tool. In some examples, the heater 530 includes an infrared heater, a resistive heater, an induction heater, a light emitting diode (LED) heater, and / or another type of heater. Fig.7D In the embodiment of the present invention, after a predetermined heating period in the heater 530, the support member 520 and the consolidated laminate 512 are moved to a compression molding tool 550, which includes an upper mold portion 580 having a plug 582 and a lower mold portion 570 having a cavity 574. The upper mold portion 580 and the lower mold portion 570 move together to apply pressure to the consolidated laminate 512 disposed on the web material and form a multi-layer and multifunctional thermoplastic composite structure.

[0080] The manufacturing method of the multilayer and multifunctional thermoplastic composite structure according to the present disclosure enables component consolidation and eliminates separate parts and joining steps (e.g., welding). The manufacturing method is capable of integrating structural areas and non-structural areas into the same component through a one-step process, while traditional molding methods use a two-step molding process. The manufacturing method eliminates the secondary steps of applying and bonding functional layers by integrating functional layers during compression molding. The manufacturing method reduces the manufacturing cycle time to achieve vehicle applications. The manufacturing method is capable of producing high-strength / rigidity thermoplastic composite systems with at least 40% mass savings compared to metal solutions. Compared to thermosetting composites, the manufacturing method also enables greater recovery and recycling potential.

[0081] The example of discontinuous fiber reinforced material includes short unidirectional tape or nonwoven mat. Short unidirectional tape includes reinforcing fibers attached to or embedded in substrate or backing layer, and optionally includes pre-impregnated thermoplastic resin. In some instances, instead of pre-impregnated resin or in addition to pre-impregnated resin, resin is supplied to the mold cavity. In some instances, short unidirectional tape is cut into a length less than 2 inches. Suitable reinforcing fibers include carbon fiber (such as carbon black, carbon nanotubes, talcum, fiber derived from polyacrylonitrile, cellulose precursor and / or asphalt precursor), glass fiber (such as fiber glass, quartz), basalt fiber, aramid fiber (such as, poly-p-phenylene terephthalamide, polyphenylene benzobisoxazole (PBO)), and combinations thereof. In some instances, reinforcing fibers are pre-impregnated with thermoplastic polymer matrix. In some examples, the thermoplastic polymer matrix and / or resin is selected from polyetheretherketone (PEEK), polyetherketoneketone (PEKK), polyphenylene sulfide (PPS), polyetherimide (PEI), low melting point PEEK (LMPEEK), polyaryletherketone (PAEK), and combinations thereof.

[0082] Examples of TRP layers include insulating materials, flame retardant materials, and / or intumescent materials. Examples of flame retardant materials include fabrics impregnated with flame retardants such as aluminum tetrahydrate (ATH) and ammonium polyphosphate (APP). Examples of intumescent materials include expanded graphite (EG). When heated above a predetermined temperature, the intumescent material expands and forms a protective charcoal to act as a fire barrier. In some examples, the predetermined temperature corresponds to the temperature encountered during a thermal runaway event.

[0083] Examples of EMI layers include woven metal mesh, continuous or discontinuous flexible fabrics, coated yarn, metal sheet, perforated metal sheet, or metal-coated fiber fill material.

[0084] The foregoing description is essentially only exemplary and is absolutely not intended to limit the present disclosure, its application or use. The broad teachings of the present disclosure can be implemented in various forms. Therefore, although the present disclosure includes specific examples, the true scope of the present disclosure should not be limited thereto, because after studying the drawings, the specification and the following claims, other modifications will become apparent. It should be understood that one or more steps in the method may be implemented in different orders (or simultaneously) without changing the principles of the present disclosure. In addition, although each embodiment is described above as having certain features, any one or more features described with respect to any embodiment of the present disclosure may be implemented in any other embodiment and / or combined with the features of any other embodiment, even if the combination is not explicitly described. In other words, the embodiments are not mutually exclusive, and the mutual replacement of one or more embodiments is still within the scope of the present disclosure.

[0085] Various terms are used to describe the spatial and functional relationships between elements (e.g., between modules, circuit elements, semiconductor layers, etc.), including "connected," "engaged," "coupled," "adjacent," "next to," "on top of," "on," "under," and "disposed." Unless explicitly described as "directly," when describing the relationship between a first element and a second element in the above disclosure, the relationship can be a direct relationship in which no other intervening elements exist between the first element and the second element, or an indirect relationship in which one or more intervening elements exist between the first element and the second element (spatially or functionally). The phrase "at least one of A, B, and C" as used herein should be interpreted to mean a logical (A or B or C) using a non-exclusive logical OR, and should not be interpreted to mean "at least one A, at least one B, and at least one C."

[0086] In the drawings, the direction of the arrows, as shown by arrows, generally demonstrates the flow of information (such as data or instructions) related to the diagram. For example, when component A and component B exchange various information but the information transmitted from component A to component B is related to the diagram, the arrow may point from component A to component B. Such a unidirectional arrow does not mean that no other information is transmitted from component B to component A. In addition, for the information transmitted from component A to component B, component B may send a request for the information to component A or a receipt of the information.

Claims

1. A method for manufacturing a multilayer and multifunctional thermoplastic composite laminate, comprising: supplying a plurality of reinforcement layers comprising reinforcing fibers and a thermoplastic resin to a batch press; supplying at least one functional layer adjacent to the plurality of reinforcing layers to the batch press, wherein the at least one functional layer is selected from an electromagnetic shielding layer and a thermal runaway protection layer; and The plurality of reinforcement layers and the at least one functional layer are heated and pressed to form a composite laminate.

2. The method according to claim 1, wherein the at least one functional layer comprises: a first functional layer disposed on one side of the plurality of reinforcement layers; and A second functional layer is disposed on an opposite side of the plurality of reinforcement layers.

3. The method of claim 1, further comprising cooling the composite laminate using the batch press after pressing and heating.

4. The method according to claim 1, further comprising: placing the composite laminate in a compression molding tool; disposing a discontinuous fiber reinforcement material in the compression molding tool; and consolidating the discontinuous fiber reinforcement material with the composite laminate to form a multilayer and multifunctional thermoplastic composite structure, wherein the discontinuous fiber reinforcement material flows into the reinforcing features of the mold cavity.

5. The method of claim 4, wherein the discontinuous fiber reinforcement material comprises chopped unidirectional tapes comprising reinforcing fibers selected from the group consisting of carbon fibers, glass fibers, basalt fibers, aramid fibers, and combinations thereof.

6. The method of claim 4, further comprising coating the multi-layered and multifunctional thermoplastic composite structure.

7. The method of claim 6, further comprising curing the coating.

8. The method of claim 4, wherein the compression molding tool includes a heater.

9. The method of claim 8, wherein the heater comprises an induction heater.

10. The method of claim 1 further comprising arranging the composite laminate on a support member comprising a frame defining an interior cavity and a mesh material extending over the interior cavity between edges of the frame.

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